Doku-18501 - GB-s - Ban Pha Pass

kupke + wolf gmbh kupke + wolf gmbh
Hägerstr. 22 Werkstraße 226

27321 Thedinghausen / Germany 19061 Schwerin / Germany
Spare parts and other components

Our range of supply for world-wide support
Phone
+49 (385) 64014 - 62
Fax
+49 (385) 64014 - 14
Email
Spares@KuWo.com
D - 27321 Thedinghausen D - 19061 Schwerin

Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
Fax +49 (0) 4204 9165 65 Fax +49 (0) 385 640 14-14
Spare parts and other components

Our range of supply for world-wide support
Of course Kupke + Wolf is able to supply any required spares
for our modules within shortest time to any destination around
the world by sea or by air.
We work together with well-known world-wide courier services

to guarantee a trouble-free operation of our fuel oil systems
at any time and any place of the world.
If requested we are able to store spares for our customers

in our central warehouse to dispatch the goods within 24 hours.
Beside the production of fuel oil modules Kupke + Wolf also

supplies all kinds of components, systems and spares
of well-known manufacturers such as:
- Oily-water separators (HEISHIN-Pump Works)
- Viscosity control systems
- Fuel oil blending units
- bunker control systems
- flowmeters for most fluids
- filtration units (e.g. automatic filters)
- gear pumps, centrifugal pumps, screw pumps
- shut-off valves, ball valves, quick-closing valves
- fittings (e.g. thermometers, manometers)
- steam-, thermal oil- and electrical-operated heaters
We are proud of our wide range of supply which allows us

to meet most of our customers requirements.
Just ask us about your demands and we surely can fulfil them.

Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
Fax +49 (0) 4204 9165 65 Fax +49 (0) 385 640 14-14
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Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
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Kupke + Wolf GmbH Kupke + Wolf GmbH
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
Documentation
for
fuel oil supply and
booster module
Type: KAH-8-C60-2D
Customer: MPC Münchmeyer
Petersen Marine GmbH
Order no.: 84-0027-6112-01
Project no.: 84-0775
Shipyard: Nam Trieu Shipbuilding
Industry Company / Vietnam
Type of vessel: 700 TEU Container
Vessel
Hull no.: NT27
Com.: 18.501
Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Contents
A. ............................................................. General technical information
.........................................................................................................Technical specification
............................................................................................................General arrangement
........................................................................................................................... P+I diagram
....................................................................................................................................Item list
........................................................................................................................ Spare part list
B. .............................................General danger and safety information
C./D. .................................................................Start-up/ Commissioning

............................................................Start-up for fuel oil supply and booster module
......................................................................Flushing instructions for booster module
E. ................................................................................................. Electricity
.........................................................Main control cabinet (Circuit diagram and parts list)
............................................................. Description and allocation of the keypad TD 200
...................................Control cabinet for supply pumps (Circuit diagram and parts list)
.................................Control cabinet for booster pumps (Circuit diagram and parts list)
................................................................ Distribution box (Circuit diagram and parts list)
.......................................................................................... Spare parts for control cabinets
1. ....................................................................................Pumps with drive

.................................................... Operating instructions screw spindle pumps (series K)
.............................................Operating and maintenance instructions for electric motors
2. .......................................................................................................... Filter
........Description and operating instructions for duplex filter 2.04.5.6.110.210 with PDI
.........Description and operating instructions for the back-flushing filter type 6.62 Gr.04
3. ............................................................................................... Flow meter

.................................................................................................................. Maintenance VZO
4. ........................................................................................................ Tanks
..............................................................................................................................Mixing tank
............................................................................... Compensation damping pressure tank
................................................Mounting and operating instructions for float switches SR
5. .......................................................................................Heat exchanger
.............................................................................Instructions for shell and tube heater MX

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
6. ................................................................Viscosity measuring system

.......................................................................................................Viscosimeter series V92
............................................................. Instruction manual for FCX-CII series transmitters
..................................................................Operating instructions for industry controller 92
7. .....................................................................................Pressure control
...................................................................Operating instructions for pressure relief valve
8. ..................................................................... Instruments and sensors

.............................................................................................Instructions for pressure switch
9. ........................................................................Heating medium control

................................................ Installation and operating manual for motor control valves
............................................. Motor control valve in two way form 421… (Technical data)
..................................................................Operating instructions for electric actuator 4e1
..............................................................Operating and installation instructions for strainer
....................Operating and installation instructions for ball float steam traps CONA SC
10. ..................................................................................................... Valves

..............................................................................................................Change over valves
............................................................................................................................. Ball valves
.......................................................................................................................Shut-off valves
..................................................................................................................Non-return valves
.........................................................................................................................Safety valves

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
A. General
technical
information
ATTENTION!
It is not allowed to operate the pumps of fuel oil supply and
booster module, if the viscosity of used fuel is less than 4 mPas.
ATTENTION!
Pay attention at installation and operation of the fuel oil supply
and booster module on board that pressure surges will be
avoided in the fuel oil pipes from/to engine.

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Ingenieurbüro • Anlagenbau • Vertrieb
TECHNICAL SPECIFICATION
FOR FUEL OIL SUPPLY AND BOOSTER MODULE:
Customer: MPC Münchmeyer Petersen Marine GmbH

Project no.: 84-0775
Shipyard: Nam Trieu Shipbuilding Industry Company / Vietnam
Type of vessel: 700 TEU Container Vessel
Hull no.: NT 27-30
Manufacturer: kupke + wolf gmbh
Com. no.: 18501
Module type: KAH-8-C60-2D
BASIC TECHNICAL DATA:
MAIN DIESEL ENGINE:

diesel engines manufacturer: Caterpillar Motoren GmbH & Co. KG
engine type: 8 M 43C
engine max. output: 7,200 kW
fuel oil: Heavy Fuel Oil (HFO) IF380
ISO 8217-F-RMK 35 (380 cSt at 50 °C)
Marine Diesel Oil (MDO)
ISO 8217-F-DMB (2.5 - 11 cSt at 40 °C)
specific fuel consumption: 176 g/kWh + 5 % (MDO)
calculated HFO density: 0.889 kg/dm³
max. HFO consumption (100 %): 1,574 l/h
filter mesh automatic back-flushing filter: 10 µm absolute
viscosity at module outlet: 9.7 mPa s (=11 mm²/s at 0.889 kg/dm3 )
max. temperature at module outlet: 141 °C
heating medium (heater): steam, 0.7 MPa (165 °C)

heating medium control valve kvs value: 4
heating medium (trace heating): steam, 0.7 MPa
assumed module inlet temp.: 80 °C

calc. mixed temp. in mixing tank: 121 °C
assumed thermal loss between inlet
to engine and return to mixing tank: 3.3 °C
classification: GL
voltage: 3 x 440 V
frequency: 60 Hz
03/07/2006 ts18501_e-mail 1/9
D-27321 Thedinghausen Werkstraße 226 Deutsche Bank Bremen Geschäftsführer

Hägerstraße 22 19061 Schwerin (BLZ 290 700 50) Kto. 1 007 004 Paul Kupke, Jürgen Wolf
Deutsche Bank Holm
Telefon (0 42 04) 91 65 - 0 Telefon (0385) 640 14 - 0 (BLZ 200 700 00) Kto. 5 924 824 Amtsgericht
Telefax (0 42 04) 91 65 - 65 Telefax (0385) 640 14 - 14 Postbank Hamburg Pinneberg HRB 1380
(BLZ 200 100 20) Kto. 1642 55 205 Ust.-ID-Nr. DE 116735004
SUPPLY PUMP:
capacity: 2.9 m³/h
design pressure: 0.5 MPa
operating viscosity approx.: 76 mm²/s
minimum operating viscosity for MDO service: 4.6 mm2 /s
power absorbed at 700 mm²/s (cSt): 0.97 kW
electric motor:
power: 1.32 kW
revolution: 1,720 rpm
insulation class: F
protection class: IP55
BOOSTER PUMP:
capacity: 5.8 m³/h
design differential pressure: 0.5 MPa
operating viscosity approx.: 18 mm²/s
minimum operating viscosity for MDO service: 4.6 mm2 /s
power absorbed at 700 mm²/s (cSt): 2.43 kW
electric motor:
power: 2.6 kW
revolution: 3,460 rpm
insulation class: F
protection class: IP55
HEATER:
calculated heating capacity: 62 kW
saturated steam temp.: 165 °C
saturated steam pressure: 0.7 MPa
max. saturated steam consumption: 107 kg/h
capacity of each heater: 100 %
fouling margin (on surface) of each heater: 20 %
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Deutsche Bank Holm
PIPING DIMENSIONS:
HFO inlet into the module: DN 40
MDO inlet into the module: DN 40
fuel oil outlet of the module: DN 50

fuel oil return to the module: DN 50
fuel oil return to daytank: DN 50
steam inlet: DN 20
condensate outlet: DN 20
MODULE DIMENSIONS:
L (length): 3,500 mm
B (width): 1,000 mm
H (height): 2,100 mm
Hm (height for maintenance work) 2,300 mm
weight: approx. 3,000 kg
BASIC MODULE DESIGN DATA:

max. operating pressure: 1.0 / 1.6 MPa
in supply part / booster part of module
max. operating temperature: < 150 °C
03/07/2006 ts18501_e-mail 3/9

Deutsche Bank Holm
PRESSURIZED FUEL OIL SUPPLY AND BOOSTER MODULE

TYPE: KAH-8-C60-2D
P & I DIAGRAM no.: KAH-8-C60-2D-1/A/P
MAIN COMPONENTS
1. CHANGE OVER VALVE, POS. 10.1
1 pc. 3/2-way valve, manual operated. The valve is equipped with end position switches
for remote indication of valve position.
The change over from HFO service to MDO service at 100 % HFO consumption will
cause a temperature gradient of 3 °C/min (theoretic value; mixing tank volume 99 l).
2. SUCTION FILTER, POS. 2.1
1 pc. Duplex filter; maker BOLL&KIRCH, as pump’s protection filter. Filter mesh 200 µm
absolute. The filter is equipped with a differential pressure indicator for controlling
the filter pollution. The filter is heatable.
3. SUPPLY PUMPS, POS. 1.1, 1.2
2 pc. Screw pumps; maker KRAL, with mechanical seal, complete with safety valves with
full capacity, non-return valves and closing valves. One pump is working while the
other pump is in stand-by.
The pumps are equipped with electric driving motors and stand-by automatics.
4. PRESSURE CONTROL SYSTEM, POS. 7.1
1 pc. Pressure control valve; maker KRACHT, for controlling the pressure of the supply
pumps. The valve is a directly spring operated relief valve. Pressure range
adjustable between 0.2 – 0.5 MPa.
The valve is equipped with bypass and closing valves.
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Deutsche Bank Holm
5. AUTOMATIC BACK-FLUSHING FINE FILTER, POS. 2.2
1 pc. Automatic filter; maker BOLL&KIRCH, filter mesh 10 µm absolute. The automatic
back-flushing fine filter is equipped with an alarm of filter pollution.
The filter control is integrated in main control cabinet on the module.
The filter is heatable and equipped with bypass and closing valves.
6. CONSUMPTION MEASURING SYSTEM, POS. 3.1
1 pc. Flow meter with roller counter; maker AQUAMETRO, for indicating the fuel oil
consumption of the engine.
The flow meter is equipped with closing valves and bypass valve.
7. PRESSURE MIXING TANK WITH ACCESSORIES, POS. 4.1
1 pc. Pressure tank with manual degassing equipment:
capacity approx.: 99 liter

max. working pressure: 1.0 MPa
test pressure: 1.5 MPa
max. working temperature: 149 °C
The pressure mixing tank is equipped with:

1 float switch for level controlling
1 safety valve, opening pressure 1.0 MPa
1 manual venting valve
1 drain valve
1 thermometer
1 pressure gauge
with tank heating, rock-wool insulation and galvanized metal plate covering.
Additionally the mixing tank is equipped with a compressed air supply connection.
8. BOOSTER PUMPS, POS. 1.3, 1.4
2 pc. Screw pumps; maker KRAL, with mechanical seal, complete with safety valves with
full capacity, non-return valves and closing valves. One pump is working while the
other pump is in stand-by.
The pumps are equipped with electric driving motors and stand-by automatics.
03/07/2006 ts18501_e-mail 5/9

Deutsche Bank Holm
9. HEATERS, POS. 5.1, 5.2
2 pc. Shell and tube heat exchangers; maker AALBORG. The heat exchangers are of
counter flow type, the heated medium is flowing through the shell and the heating
medium through the pipes.
Both heaters are insulated and equipped with safety valves, bypass and closing
valves.
10. HEATING MEDIUM CONTROL VALVE, POS. 9.1
1 pc. Control valve with assembled actuating drive; maker KFM. The control valve is
driven by the output signal of the viscosity controller and controls the heating power
by means of the flow rate of the heating medium.
The control valve is equipped with strainer, bypass and closing valves.
11. VISCOSITY CONTROL SYSTEM, POS. 6.1, 6.2, 6.3
1 pc. Automatic viscosity measuring and control unit (maker VAF+KuWo), complete with:
- sensor
- sensor casing
- differential pressure transmitter
- electric driving motor
- controller for viscosity controlling (installed in ECR)
The viscosity controller is loose delivery for installation in ECR.
The sensor, including the differential pressure transmitter is factory calibrated as a

common unit and delivers a current output signal, proportional to the measured
viscosity (measuring range 4 - 20 mA respectively 0 – 50 mPa s).
Scale viscosity in mPa s.
The unit is equipped with closing and bypass ball valves.
1 pc. Viscosity indicator - analog type - installed in main control cabinet of the module.
12. CHANGE OVER VALVE, POS. 10.2
1 pc. 3/2-way valve, manual operated. The valve is designed for change over the return
stroke from the engine to mixing tank or to HFO daytank.
03/07/2006 ts18501_e-mail 6/9

Deutsche Bank Holm
13. COMPENSATION DAMPING TANK, POS. 4.2

1 pc. Pressure tank for damping of pressure peaks and quick load alternations of the fuel
oil system:
nominal capacity approx.: 19 litre
maximum working pressure: 1.6 MPa
test pressure: 2.4 MPa
maximum working temperature: < 150 °C
- with tank heating
- with rock-wool insulation
- with sheet-metal jacket covering.
CONTROL AND REGULATION OF THE MODULE
The module is controlled automatically by programmable logic controller (PLC) with

alarms and starters.
On the module are installed:

1 pc. main control cabinet
4 pc. pump control cabinets
2 pc. distribution boxes.
The main control cabinet is equipped with:

- main switch
- all required signal lamps
- starter viscosimeter
- viscosity indicator (panel meter; analog type)
- automatic filter controlling
- flushing cycle counter for automatic filter
- text display TD 200
- stand-by control for supply pumps and booster pumps
Alarms:
- supply and booster pump stand-by start (single alarm)
- low level in the mixing tank
- automatic back-flushing fine filter pollution
- viscosity alarm high/low (single alarm)
The alarms are equipped with delay times for common alarm and with undelayed potential
free contacts for the single alarms for transmission into the engine control room.
03/07/2006 ts18501_e-mail 7/9

Deutsche Bank Holm
PERFORMANCE AND MATERIALS
All piping components of the module are connected with each other through the necessary
pipes.
All electric supplied components of the module are connected with the terminal strips in the
control cabinets which are installed on the module.
The distribution boxes are equipped with single voltage source of supply for each of them.
The control cabinets are connected by maker.
All the in- and outgoing piping of the module are flange connections with counter flanges type
11 according to DIN EN 1092-1 (former DIN 2627 to 2635).
The ingoing and outgoing piping of the module for compressed air is provided with pipe
fittings.
The fit in valves have a nominal pressure class of at least 1.6 MPa.
The material of the piping is welded steel according to EN ISO 4200 (former DIN 2458).
All main components and inlets and outlets of the module are labeled with name plates in
English language.
All material and components are according to the rules and regulations of the classification
society.
The hot fuel oil pipes (with T > 60 °C) are equipped with insulation which is covered with
aluminium foil and wire-gauze.
The HFO pipes in the supply part of the module are equipped with trace heating. The heating
medium pipes are safety protected against contact where necessary.
All flange connections of the fuel oil pipes are equipped with spray protection.
The base frame is a welded construction of profile steel bars with bottom plate.
The module is painted in standard paint color RAL 6019.

The control cabinets and distribution boxes are painted in paint color RAL 7035.
The module will be tested hydrostatical and functional in the workshop without heating.
03/07/2006 ts18501_e-mail 8/9

Deutsche Bank Holm
DIMENSIONS AND COMPONENT ARRANGEMENT RESERVATION
The external module dimensions and flange positions as stated herein are referred to the
technical requirements and performance of this specification and the so resulting components
and control systems.
Supplementary modifications of the module as requested by the customer and namely changes
in capacity, performance and/or functions may lead to revised dimensions and component
arrangement.
03/07/2006 ts18501_e-mail 9/9

Deutsche Bank Holm
Item List 18501 MPC
Fuel Oil Supply and Booster Modul 84-0775
KAH-8-C60-2D Vessel NT 27 / 84-0027-6112-01
Nam Trieu Shipbuilding Industr
03.07.2006
Pos. Qty Title / Type DN PN Art.-No.
1.1 1 Screw pump in flange design 16 PUMPS13

KFUG 42 + 90 32
1.1.1 1 motor, electr. driven, 4 poles, no. 90S, size B5 MOTOR8

50/60 Hz, 1.10/1.30 kW, 1,450/1,720 rpm
1.1.2 1 ball valve 25 VALVE104
2-part sealing, reduced ball, welding connectors 32
1.1.4 1 non return disc.valve ( wafer type ) 40 NORET17

SR 20.40 St 32

KFUG 42 + 90 32
1.2.1 1 motor, electr. driven, 4 poles, no. 90S, size B5 MOTOR8

50/60 Hz, 1.10/1.30 kW, 1,450/1,720 rpm


SR 20.40 St 32

KFUG 42 + 90 32
1.3.1 1 motor, electr. driven, 2 poles, no. 90L, size B5 MOTOR27
50/60 Hz, 2.20/2.61 kW, 2,800/3,460 rpm


SR 20.40 St 32

KFUG 42 + 90 32
1.4.1 1 motor, electr. driven, 2 poles, no. 90L, size B5 MOTOR27
50/60 Hz, 2.20/2.61 kW, 2,800/3,460 rpm



SR 20.40 St 32
2.1 1 duplex filter, heated 16 FILTM22
2.04.5.6 Size 110/210 40
2.1.3 1 glycerin pressure gauge 63mm rear attachment ring CrNi GAUGE64
double scale -1 to 5 bar, -0.1 to 0.5 MPa 10
Page 1
2.1.4 1 pressure gauge valve R 1/4" brass 125 GAUGE11

form A with test connection 10
2.2 1 autom. self-cleaning fine filter 16 FILTA9

6.62 Size 04, 10 µm absolute 40
2 part sealing, reduced ball, welding connectors 25

3.1 1 flowmeter, flange connectors 25 FLOW13

Contoil VZO 25 FL 130/25 25


3.1.4 1 thermometer angle - B GAUGE32

Tt = 63 mm (0-200°C) 15
4.1 1 mixing tank, insul. + traceheating TANKS6

99 ltr standard
4.1.1 1 Float type switch, 2 contact 16 FLOAT21

SR1 AX 350 L A2-GL S1 S200 S2 S300 65
4.1.10 1 solenoid valve 25 VALVE216

10
4.1.11 1 sleeve ball valve 25 VALVE191
MS 1/4" 10
4.1.12 1 non return valve (compressed air) 100 NORET39

10
4.1.2 1 safety valve, set point 10 bar 100 VALVS121

APZ 3.1 B n. EN 10204 15

2 part sealing, reduced ball, welding con., lock-device 20
double scale 0 to 10 bar, 0 to 1 MPa 10

4.1.7 1 thermometer angle - B GAUGE33

Tt= 100 mm (0-200°C) 15

SR 20.40 St 50
4.2 1 compensating damping tank, insul. + traceheating TANKS4
19 ltr standard


Page 2

5.1 1 shell + tube heater (steam ) HEATT57

MX 15-2P, L=1,000 mm



2 part sealing, reduced ball, screwing con., lock-device 15

APZ 3.1 b n. EN 10204 15
5.1.7 1 stop valve with gland seal (straightway type) 16 VALVE320

Figur 12.006 20

Figur 12.006 20
5.1.9 1 thermometer straight - B GAUGE37

Tt = 63 mm ( 0-200°C) 15
5.2 1 shell + tube heater (steam ) HEATT57

MX 15-2P, L=1,000 mm




APZ 3.1 b n. EN 10204 15

Figur 12.006 20

Figur 12.006 20
6.1 1 measuring flange, complete VISCS1

0-50 steel/straight line 50
6.1.1 1 electric gear motor, complete VISCO12
0.09 kW, 44/53 rpm, i=30:1
6.1.2 1 viscosimeter housing VISCS2

Page 3


6.1.6 1 thermometer straight - B GAUGE37
Tt = 63 mm ( 0-200°C) 15
6.2 1 differential pressure transmitter VISCO38

FKKX35V4-AKAYY-AA, 4 - 20 mA
6.3 1 3-Point-Step-Controller 92701e-99xkuw1 VISCO1
7.1 1 pressure regulating valve 16 VALVC49

SPVF25K2F1A05 = 2 - 5 bar, 150°C, SAE flange port 25


8.1 1 pressure switch 1-10 bar with female thread 24 SWITC9

900.2378.905 10
double scale 0 to 10 bar, 0 to 1 MPa 10
8.1.2 1 pressure gauge dashpot MS GAUGE21

10

8.2 1 differential pressure switch 24 SWITC16
0 - 4 bar, 920.2376.937 10
double scale 0 to 16 bar, 0 to 1.6 MPa 10

10

10

double scale 0 to 16 bar, 0 to 1.6 MPa 10

9.1 1 motor control valve (2/2-way) kvs=4 16 VALVC79

GGG-40.3 20
Figur 12.006 20

Figur 12.006 20

Figur 12.006 20
Page 4
9.1.4 1 Y-strainer, 250 µm, GG 25 16 STRAI13

Fig. 12.050 20
9.2 1 Float-steam trap 16 FITTI147

CONA-SC R14 C22.8 20
Figur 12.006 20

Figur 12.006 20
Figur 12.006 20
9.3 1 Float steam trap 16 FITTI146

CONA-SC R14 C22.8 15

Figur 12.006 15

Figur 12.006 15
Figur 12.006 15
10.1 1 3/2-way change over valve, compact 16 VALVE403

776 with 3.1 B 32
10.1.2 1 2 end position switches VALVE432

Bernstein TI-SU 1 ZW

SR 20.40 St 32
10.2 1 3/2-way change over valve, compact 16 VALVE405

776 with 3.1B 50
Page 5
kupke+wolf gmbh * germany * phone 0385 640 14 0 * fax 0385 640 14 14
LIST SPARE PARTS and TOOLS Nam Trieu Shipbuilding

pressurized heavy fuel oil supply project: 18.501
and booster module berichtigt am 21.3.06 DW
pos.no. pcs title type DN PN
for module
100-1 1 safety valve, set point 1,6 MPa SAFE-TCP 1/2" 100
for back flushing filter (pos. 2.2):

150-1 1 key (short) for unscrewing the filter element No. 7
150-3 1 compressed air cleaning gun 5.01, No. 2 500 LG
spar-18501 / 18.501 18.07.2006 1/1

B. General danger
and safety
information

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Werkstraße 226
D-19061 Schwerin/Wüstmark
kupke+wolf gmbh Phone:

Fax:
E-mail:
+49-385-640 14-0
+49-385-640 14-14
info@kuwo.com
Hägerstraße 22
Manufacturer: kuwo D-27321 Thedinghausen
Phone: +49-4204-9165-0
Prepared on: 27.07.2006
General danger and safety information Fax: +49-4204-9165-65
Project: 18.501 Customer: MPC Münchmeyer Petersen
Revision: ---- Marine GmbH
Language: English Order no.: 84-0027-6112-01
Industry Company / Viet nam
Hull no.: NT27
2.1 GENERAL
2.1.1 Introduction
All responsible persons and those who work with KUPKE+WOLF fuel oil supply
and booster modules must read, understand and observe in all points this
information.
The complete technical documentation should always be kept in the vicinity

the fuel oil supply and booster module.
This documentation refers to details of particular importance for the deployment of

this supply module.
It is very important that all responsible persons acquaint with of the present
documentation. Errors on the fuel oil supply and booster module can only be
avoided and a trouble-free operation guaranteed by knowledge of this
documentation.
We recommend you to read this documentation carefully prior to functioning. The

manufacturer doesn’t take any responsibility for damages or malfunctions resulting
from the non-observance of this documentation!
In case of difficulties, please contact the after sales service and/or spare parts
department or one of our representatives. They will be pleased to help you.
For possible changes in illustrations and information included in this

documentation, in case of improvement or technical modifications in the fuel
oil supply and booster module, all rights reserved.
Page 1 of 5
Werkstraße 226

Fax:
E-mail:
+49-385-640 14-0
+49-385-640 14-14
info@kuwo.com
Hägerstraße 22
Phone: +49-4204-9165-0
Hull no.: NT27
2.1.2 Application
Fuel oil supply and booster modules are used among others, for supplying main
engines on board of sea going ships. They are designed as a complete module.
In order to deploy an optimal fuel oil supply and booster module for the
corresponding application, the designs are tuned to the complete system, the fuels
and lubricants as well as the flow rate, temperature and the pressure of the
medium.
The fuel oil supply and booster module is only designed for the application
indicated in the chapter A “General technical information”.
Never use the supply module out of its contractual application (cf. chapter A
“General technical information”), without asking the after sales service of
KUPKE+WOLF GmbH for advice (the address can be found in the following
chapter). Otherwise the guarantee becomes invalid.
2.1.3 Copyright
The copyright to this documentation remains with KUPKE+WOLF GmbH. This

documentation is intended for the assembly personnel, operators and supervisors.
It contains prescriptions and drawings of technical nature that may not be copied,
neither completely or in part, nor be distributed or used in an unauthorised manner
for competition purposes or be disclosed to third parties.
Kupke+Wolf GmbH
Werkstraße 226
D-19061 Schwerin / Wüstmark
Phone: +49(0)385-640 14-0
Fax: +49(0)385-640 14-14
E-mail: info@kuwo.com
Internet: www.kuwo.com
Kupke+Wolf GmbH
Hägerstraße 22
D-27321 Thedinghausen, Germany
Phone: +49(0)4204-9165-0
Fax: +49(0)4204-9165-65
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2.2 Safety
2.2.1 Symbols and notices
2.2.1.1 Warning symbol
Hazard to life and limb of persons. Observe these notes and

behave in all cases extreme cautiously.
Please forward all notes for the safe system at work to other
users as well.
Further on, follow the generally applicable safety regulations
and regulations for the prevention of accidents.
2.2.1.2 Important symbol

Special attention! Observe directives, regulations, indications and
the correct sequence of operations to prevent damages and
destruction of the system and/or system components.
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2.2.2 Notices for the warning symbol

The following notes for work safety are to be observed.
- The fuel oil supply and booster module has been manufactured according to
the actual technical standards and is operationally reliable. However,
hazards can emanate from this system if it is used improperly by untrained
personnel or not for the intended purpose.
- Each person who is involved in the premises of the user with the assembly,
dismantling, disassembly, start-up, operation and servicing (inspection,
maintenance, repair) of the fuel oil supply and booster module must have
read and understood the complete documentation and in particular this
chapter (2.2). We recommend the user to confirm this in writing form.
- The fuel oil supply and booster module can only be used for the technical
purpose agreed upon in the contract. Any other use than this one is not
considered to be normal use. The manufacturer will not be liable for any
damage resulting. It is only risk of the user.
- Normal use also includes observance of the assembly, dismantling and

disassembly, start-up, operating and servicing conditions prescribed by the
manufacturer.
- Only authorised, trained and instructed personnel are allowed to operate,

maintain and repair the functional module. These personnel must get special
instruction as regards possible hazards.
- To avoid unnecessary risks, all responsibilities for assembly, dismantling

and disassembly, start-up, operation and servicing must be clearly defined
and complied.
- For all work concerning assembly, dismantling and disassembly, start-up,

operation, adaptation and servicing, the shut-off procedures have to be
observed.
- Any working method that impairs the safety of the fuel oil supply and booster
module is prohibited.
- The operator must ensure that no unauthorised persons work on the system.
- The operator is obliged to report immediately any alterations of the fuel oil
supply and booster module that impair the safety to the responsible safety
engineer.
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- The user is obliged to operate the fuel oil supply and booster module only in
perfect condition.
- The user must ensure cleanness and clarity of the system through
corresponding instructions and controls.
- Arbitrary rebuild and modifications that influence the safety of the fuel oil
supply and booster module are not allowed.
- Basically, all work on the supply module may be carried out only when the
system is turned off.
- Prior to performing any work on the functional module, be sure that the
system is depressurised. Furthermore, its drives and additional equipment
are to be so protected that they cannot be switched on unintentionally.
This is possible means a lockable local switch (not in scope of supply).
Extreme caution is required when handling components that are still
warm.
- After servicing and prior to start-up and following repairs, verify that all
protection devices are fitted.
- Remove protection devices only when the system is turned off.
- The lifting capacity of hoisting gears for installation must be sufficiently rated
(cf. chapter A “General technical information”).
- Fasten the fuel oil supply and booster module only to the existing lifting
eyelets.
- Whenever having carried out an electric installation or repair of the electric

equipment, the protective measures installed have to be checked (e.g.
earthing resistance).
- The local safety regulations and regulations for the prevention of accidents
apply in each case to the operation of the fuel oil supply and booster
module.
2.2.3 Environmental protection and dangerous substances
For handling the fuel oil supply and booster module, it is absolutely
necessary to comply with the provisions regarding environmental
protection and dangerous substances!
Page 5 of 5
C./D. Start-up/
Commissioning
ATTENTION!
It is not allowed to operate the pumps of fuel oil supply and
booster module, if the viscosity of used fuel is less than 4 mPas.
ATTENTION!
Pay attention at installation and operation of the fuel oil supply
and booster module on board that pressure surges will be
avoided in the fuel oil pipes from/to engine.

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D-27321 Thedinghaus en
Prepared on: 27.07.2006 Start-up / Commissioning Phone:

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Com. number: 18.501 Customer: MPC Münchmeyer Petersen
Revision: --- Marine GmbH
Hull no.: NT27
Start-up
for
fuel oil supply and booster module
steam heated
Take care that no water or moisture penetrates in the module.
Operation data:
Operation pressure: 1.0/1.6 MPa max.
Test pressure: 1.5/2.4 MPa
Operation temperature: 149 °C max.
The fuel supply system is executed and accepted according to the classification society GL.
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Start-up with gas oil or diesel oil
Always activate cooler when engine is running with gas oil or diesel
oil.
Before switching over to MDO operation turn off trace heating.
1. Open all valves to pressure gauges and pressure switches.
2. Take care that following valves and ball valves are closed:
Title Pos. no.
By-pass pressure control valve 7.1.3
Inlet automatic filter 2.2.1
Outlet automatic filter 2.2.2
Inlet flow meter 3.1.1
Outlet flow meter 3.1.2
Vent mixing tank 4.1.4
Drain mixing tank 4.1.3
Fuel inlet heater I + II 5.1.1, 5.2.1
Fuel outlet heater I + II 5.1.2, 5.2.2
Vent heater I + II 5.1.4, 5.2.4
Drain heater I + II 5.1.5, 5.2.5
Inlet viscosimeter 6.1.3
Outlet viscosimeter 6.1.4
Steam inlet (all)
Inlet trace heating 9.4.1
Outlet steam control valve 9.1.2
By-pass steam control valve 9.1.3
Inlet compensation tank 4.2.1
Aerating compensation tank 4.2.3
Drain compensation tank 4.2.2
3. Open following valves and ball valves:

Title Pos. no.
Inlet supply pump I + II 1.1.2, 1.2.2
Outlet supply pump I + II 1.1.3, 1.2.3
Inlet pressure control valve 7.1.1
Outlet pressure control valve 7.1.2
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By-pass automatic filter 2.2.3

By-pass flow meter 3.1.3
Inlet booster pump I + II 1.3.2, 1.4.2
Outlet booster pump I + II 1.3.3, 1.4.3
By-pass heater I + II 5.1.3, 5.2.3
By-pass viscosimeter 6.1.5
Outlet condensate 5.1.8, 5.2.8,
9.2.1, 9.2.2,
9.3.1, 9.3.2
Inlet steam control valve 9.1.1
Manifold valve at DP-transmitter (viscosimeter) all
4. Turn 3-way-ball valve pos. 10.2 at return pipe to mixing tank into position “Return To
Mixing Tank”. This position has to be kept for normal operation of fuel oil supply
and booster module.
5. Open ball valves “Aerating compensation tank”, pos. 4.2.3 and “Drain
compensation tank”, pos. 4.2.2 until compensation tank is empty. Then close ball
valves “Aerating compensation tank” and “Drain compensation tank”.
6. Start-up main control cabinet

Make sure that the pumps, the viscosimeter, the viscosity controller and automatic
filter are switched “OFF” before switching on main control cabinet.
Pumps to be switched off at separate pump control cabinets.
Viscosity controller to be switched off at ECC.
After that switch on the main switch S1 at the main control cabinet. Indication lamp
H1 “Power ON” lights up at the main control cabinet.
7. Turn 3-way-ball valve pos. 10.1 at FO inlet into position “MDO Service”. Indication
lamp H3 for MDO service lights up at the main control cabinet.
8. Start-up automatic filter, pos. 2.2 in by-pass operation

The ball valves “Inlet automatic filter”, pos. 2.2.1 and “Outlet automatic filter”,
pos. 2.2.2 are closed. The ball valve “By-pass automatic filter”, pos. 2.2.3 is
opened.
Make sure that supply line of compressed air is opened.
Adjust the compressed air filter regulator of the automatic filter up to 3.5 - 4 bar.
9. Open all valves between diesel oil daytank and module.
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10. Vent the suction filter, pos. 2.1 (see separate instruction manual in chapter 2 “Filter”
of this documentation).
Take care that only one filter chamber of the suction filter is in operation and the
other filter chamber is in reserve after that.
11. Start-up pumps, pos. 1.1, 1.2, 1.3, 1.4

Make sure that the selection switches S2 and S4 at the control cabinets for supply
pumps and booster pumps are in position “0” before starting pumps. After that switch
on the main switches S1 and S3 at the control cabinets for supply pumps and booster
pumps.
Observe the rotary direction of the pumps by shortly starting the pumps
using the selection switches S2 and S4 at the pump control cabinets.
11.1 Start-up supply pump 1, pos. 1.1, manually

Start supply pump 1 – selection switch S1 at the control cabinet for supply pumps in
position “Man.”.
Vent the mixing tank using the ball valve “Vent mixing tank”, pos. 4.1.4. When the
mixing tank is completely filled, close ball valve “Vent mixing tank”.
If it is necessary to aerate the mixing tank manually, open the shut-off valve
(pos. 4.1.11). When the necessary air volume is reached, overcrowding safety
mechanism (solenoid valve, pos. 4.1.10) breaks off the air supply. After that close
shut-off valve (pos. 4.1.11) again. Herewith aerating process is complete.
This manually aerating process shall carried out regularly every two weeks.
If pressure drops down in the system after manually aerating process, it is
possible that mixing tank alarm will be set off. In this case corresponding alarm
message (“mixing tank level low”) has to be signed at the TD 200-display at
first. After that open ball valve “Vent mixing tank”, pos. 4.1.4. When fuel leaks
from vent pipe close ball valve “Vent mixing tank”.
Close ball valve “By-pass flow meter”. The pressure gauge on pressure side of
pump must indicate 4 bar. If not, adjust the pressure control valve, pos. 7.1, to 4 bar.
After that check the relief valve of the pump. For this close ball valve “Inlet pressure
control valve”, pos. 7.1.1. Pressure at pressure gauge should be approx. 7 bar. If not,
adjust relief valve of the pump (see separate description in chapter 1 “Pumps with
drive” of this documentation). Open the ball valve “Inlet pressure control valve” and
“By-pass flow meter”.
Stop supply pump 1.
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Take care that both pumps do not run parallel.
11.2 Start-up supply pump 2, pos. 1.2, manually

Start supply pump 2 – selection switch S2 at the control cabinet for supply pumps in
position “Man.”.
Act according to procedure of the two last sections of pos. 11.1.
Supply pump 2 keeps on running.
11.3 Start-up booster pump 1, pos. 1.3, manually
One of supply pumps has to be running before start-up of booster

pumps.
Start booster pump 1 – selection switch S1 at the control cabinet for booster pumps
in position “Man.”.
The pressure gauge on pressure side of booster pump must indicate a minimum
differential pressure of 1 bar relating to primary pressure.
After that check the relief valve of the pump. For this close the ball valve “By-pass
viscosimeter”, pos. 6.1.5. The differential pressure should be approx. 10 bar. If not,
adjust relief valve of the pump (see separate description in chapter 1 “Pumps with
drive” of this documentation). After that open ball valve “By-pass viscosimeter”.
Stop booster pump 1.
Take care that both pumps do not run parallel.
11.4 Start-up booster pump 2, pos. 1.4, manually

Start booster pump 2 – selection switch S2 at the control cabinet for booster pumps
in position “Man.”.
Act according to procedure of the two last sections of pos. 11.3.
Booster pump 2 keeps on running.
If only start-up of pumps will carried out all the 4 pumps have to be
switched off after that.
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12. Start-up flow meter, pos. 3.1

V e r y s l o w l y a n d i n s u c c e s s i o n open ball valve “Inlet flow meter”,
pos. 3.1.1 and “Outlet flow meter”, pos. 3.1.2. Close ball valve “By-pass flow
meter”, pos. 3.1.3.
13. Start-up heater

Please note: In all the 3 operating instances of heaters rules:
If one supply pump and one booster pump are running the pressure in the
mixing tank must be 4 bar and fuel pressure to engine should be 5 bar or more.
However minimum differential pressure must not be less than 1 bar.
13.1 Heater 1, pos. 5.1, in operation, heater 2 in stand-by

Open ball valve “Inlet heater 1”, pos. 5.1.1 and “Outlet heater 1”, pos. 5.1.2. Close
ball valve “By-pass heater 1”, pos. 5.1.3. Open ball valve “Outlet heater 2”,
pos. 5.2.2.
Fill up heater 1 with diesel oil and vent the heater using ball valve pos. 5.1.4.
13.2 Heater 2, pos. 5.2, in operation, heater 1 in stand-by

Open ball valve “Inlet heater 2”, pos. 5.2.1 and “Outlet heater 2”, pos. 5.2.2. Close
the ball valve “By-pass heater 2”, pos. 5.2.3 and “Inlet heater 1”, pos. 5.1.1.
Fill up heater 2 with diesel oil and vent the heater using ball valve pos. 5.2.4.
13.3 Both heaters in operation (emergency function)

At first open inlet and outlet ball valves of both heaters. After that close both by-pass
ball valves (pos. 5.1.3 and 5.2.3).
14. Start-up automatic filter, pos. 2.2

Switch on voltage of automatic filter control using switch S9 “Automatic filter ON” at the
main control cabinet. Indication lamp H14 lights up.
Open ball valve “Inlet automatic filter”, pos. 2.2.1. Fill up automatic filter with diesel
oil. After that open ball valve “Outlet automatic filter”, pos. 2.2.2. Close the ball valve
“By-pass automatic filter”, pos. 2.2.3.
Check time settings of the filter control on TD 200-display using key F3:
- Flush time 10 sec
- Blocking time 5 – 8 minutes
- Flushing cycle time 2 hours
For adjustment of time settings see separate instruction manual for TD 200 (in
chapter E “Electricity” of this documentation).
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15. Start-up viscosimeter, pos. 6.1

Open the ball valves “Inlet viscosimeter”, pos. 6.1.3 and “Outlet viscosimeter”,
pos. 6.1.4. Close the ball valve “By-pass viscosimeter”, pos. 6.1.5.
Switch on the viscosimeter motor at the main control cabinet using switch S2
“Viscosity motor OFF-ON”. Indication lamp H2 lights up.
Observe the rotary direction of viscosimeter motor.
For the complete start-up of the viscosimeter see separate instruction manual (in
chapter 6 “Viscosity measuring system” of this documentation).
16. Set pumps in automatic operation
16.1 Set the pump selection switches S2 and S4 at the control cabinets for supply pumps
and booster pumps in position “Auto.”. Indication lamps “Automatic” for supply
pumps and for booster pumps light up at the main control cabinet (tableau for pump
control).
16.2 Now it is possible to switch on at first the requested supply pump and after that - with
time delay - the requested booster pump using the selection switches for supply
pump and for booster pump at main control cabinet (tableau for pump control). Then
the other supply resp. booster pump is in stand-by operation.
If time delay during switching on the booster pump was not long enough, may be
that pumps change to stand-by operation. The alarm message “stand-by alarm”
lights up on the TD 200-display. This alarm message must be signed (For this
see separate instruction manual for TD 200 in chapter E “Electricity” of this
documentation.).
After that a pump reset is to be done. Pushbutton for reset stand-by supply pumps
resp. pushbutton for reset stand-by booster pumps at the main control cabinet
(tableau for pump control) must pushed for this. The alarm message “stand-by
alarm” lights down on the TD 200-display. Indication lamp, which is integrated in
before pushed pushbutton for alarm reset, lights down also.
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17. Pumps remote controlled from ECR (Possible only, if accordingly remote
control is installed in ECR)
Make sure that all required valves for operation of pumps are opened
before pumps will be started in remote.
17.1 Set the pump selection switches S2 and S4 at the control cabinets for supply pumps
and booster pumps in position “Auto.”. Indication lamps “Automatic” for supply
pumps and for booster pumps light up at the main control cabinet (tableau for pump
control).
17.2 Push pushbutton S4 “Local/Remote control pumps” at the main control cabinet
(tableau for pump control). Indication lamp, which is integrated in this pushbutton,
lights up.
17.3 After that it is possible to operate the pumps remote controlled from ECR by
operation of the appropriate selection switches there.
If no supply pump and/or booster pump was preselected in ECR,

supply pump and/or booster pump, which was locally started, stops.
Supposing that stand-by case happens, a potential free contact (single or common
alarm) will be transmitted to ship’s alarm system. This alarm will be indicated also
on the TD 200-display at the main control cabinet of the fuel oil supply and booster
module. The alarm message has to be signed there. (For this see separate
instruction manual for TD 200 in chapter E “Electricity” of this documentation.).
The duty engineer has to investigate the reason for stand-by start.
In case of a short pressure drop a pump reset is to be done.
For this case act according to procedure of the last section of pos. 16.2.
In case of pump breakdown it is only allowed to operate the

stand-by pump manually.
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18. Operating with heavy fuel oil (HFO)
18.1 Switch on the viscosimeter motor at main control cabinet and the viscosity controller
at ECC.
18.2 Set the viscosity controller into manual operation.
18.3 Make sure that the “Steam control valve”, pos. 9.1 is completely closed. If not,
switch it off manually via viscosity controller. (See separate instruction manual for
viscosimeter in chapter 6 “Viscosity measuring system” of this documentation).
18.4 Open all “steam inlet” and “condensate outlet” valves.
18.5 Make sure that the valves “Inlet trace heating”, pos. 9.4.1 and “By-pass steam
control valve”, pos. 9.1.3 are closed.
18.6 Check the viscosity set-point of the viscosity controller.
18.7 Close the by-pass valve of the manifold valve at the DP-transmitter.
18.8 Set the viscosity controller into automatic operation.
18.9 Turn 3-way-ball valve pos. 10.1 at FO inlet into position “HFO Service”. Indication
lamp H4 for HFO service lights up at the main control cabinet.
Set MDO cooler into bypass operation.
3-way-ball valve pos. 10.2 at return pipe to mixing tank has to be turned into
position “Return To Mixing Tank” for normal operation of fuel oil supply and
booster module.
The system will be filled automatically with HFO depending on consumption of the
engine. The viscosity controller regulates automatically the viscosity to the adjusted
set-point (see separate instruction manual for viscosimeter in chapter 6 “Viscosity
measuring system” of this documentation).
Open valve “Inlet trace heating” not until the system is completely filled
with HFO or if required. During operating with HFO the trace heating shall
be set into operation.
In case of back-flushing of automatic filter will released because differential

pressure increased, indication lamp H15 “Flush. by difference pressure” lights up at
the main control cabinet and is lighting as long as a reset is done. A corresponding
alarm message will be indicated also on the TD 200-display. The alarm message
has to be signed at this display using key F2 (= reset for indication lamp H15 also).
The reason for back-flushing release has to be investigated. Insufficient HFO quality
can be a reason for this. In this case change time setting for “flushing cycle time” to a
lower value at TD 200-display using key F3.
The default value of time setting for “flushing cycle time” (see pos. 14 of this start-
up) has to be adjusted as soon as HFO of better quality has been bunkered.
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19. Switching back from HFO operation to MDO operation
Before switching over to MDO operation turn off trace heating.
Turn 3-way-ball valve pos. 10.1 at FO inlet into position “MDO Service”. Indication
lamp H3 for MDO service lights up at the main control cabinet.
3-way-ball valve pos. 10.2 at return pipe to mixing tank has to be turned into
position “Return To Mixing Tank” for normal operation of fuel oil supply and
booster module.
The inflow of MDO leads to drop down of viscosity. Because of that the viscosity
controller closes the “Steam control valve”, pos. 9.1 independently.
If the viscosity drops down below 5 mPas so the MDO cooler shall
be set in operation.
Page 10 of 10
APPENDIX / DEVIATION CONTRACT

->attention for Shipyard: Flushing instructions for booster module
=======================================================================================================
All diesel engine manufacturers require a flushing procedure of the fuel oil system
before the diesel engine is started up (see engine guide -> general flushing
procedures).
Your fuel oil system includes a supply and booster module made by kupke+wolf gmbh.
The internal tubes of our modules are sandblasted, cleaned and each module is
carefully flushed with diesel oil on the test bench.
To save the guarantee of this module (and its main components) the shipyard has
to pay attention to some additional requirements regarding flushing of the fuel oil
system including the booster module.
Our instructions:
- Flushing of the module must be effected with Marine Diesel Oil (MDO) with
minimal viscosity of 4 mPas (resp. 4.6 cSt).
- Make sure that the internal piping is cleaned and pre-flushed.
- Open the drain of mixing tank and compensating pressure tank to flush out the
rests of the conservation oil remained after flushing on the test bench.
- Flushing of the booster module has to be done from flange A or B (fuel inlet) to
flange C (outlet to engine) using the internal automatic fine filter on the module.
- The return stroke from the engine to the mixing tank has to be flushed as well.
- In order to ensure that dirt from the external pipe lines (especially from the return
pipe line of the shipyard does not get into the booster module the additional
filters should be installed before flange A or B (fuel inlet) and before flange D
(return stroke from engine = return inlet to the mixing tank). These filters should
have purity rate of min. 25 µm absolute. The filters should have a check bag or
any other possibility to control the cleanness.
- Flushing should be provided in two steps:
- Step one: Flow meter, heater, viscosimeter and compensating pressure tank have
to be closed and flushing has to be done through the bypass lines of these
components. After four hours of continuous flushing the shipyard representative
has to check the additional filters. Flushing has to continue until the filters are
clean. When the filters are clean proceed to step two.
- Step two: The bypass lines are to be closed and flushing has to be done through
the flow meter, heater, viscosimeter and compensating pressure tank. After four
hour of continuous flushing the shipyard representative has to check the additional
filters. Flushing has to continue until the filters are clean.
- As experience shows the whole flushing process should continue min. 24 hours.
If you have any further questions regarding these instructions, please don’t hesitate to
contact with us.
kupke+wolf gmbh
02.12.2004 Flushing instructions for booster module_021204-korrigiert.doc 1/1

Deutsche Bank Holm
Telefax (0 42 04) 91 65 - 65 Telefax (0385) 640 14 - 14 VR Bank eG, Schwerin Pinneberg HRB 1380
(BLZ 140 914 64) Kto. 170976 Ust.-ID-Nr. DE 116735004
E. Electricity

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25.09.01
Da.
Description and allocation of the keypad TD 200

The pumps and automatic filter are controlled by a SPS, located in the
main-cabinet.
With the key pad TD 200 it is possible to change some necessary adjustments.
The buttons allocation is fixed as follows:
F1 Automatic filter manually flush

Press button F1 to release the flushing
F2 Reset of the lamp - ”backflushing release by differential pressure”

Press button F2 to reset displayed message
F3 Changing the time settings of the filter

Press button F3 to indicate the adjusted flushing time.
After pressing the ENTER-button the displayed value starts to flash.
With the arrow keys it is now possible to increase or decrease the value.
Confirm with ENTER-button to proceed to the next step.*
Afterwards the filling up time (locking time) is indicated in the display.
By pressing the ENTER-button the value starts to flash and can also be
changed in the same way as described above.
Confirm with ENTER-button to proceed.*
At last the display switches to the adjusted flushing cycle time (automatic
flushing release) This value can also be changed in the same way as described
above.
F4 Changing the delay time for pumps st.-by start
1. Approach of the st.- by pumps after pressure-drop or breakdown

of operation pump. Range: 3 - 30 sec.
Press button F4 to indicate the adjusted delay time.
After pressing the ENTER-button the displayed value starts to flash.
With the arrow key this value can be increaded or decreased.
Confirm with ENTER-button.*
*
To prevent that the TD 200 left off in change-mode, all changes of adjustments
have to be done within 50 sec.
Afterward the TD 200 returns to display-mode automatically.
2. Delayed start of the Supply pumps after black-out
The pumps re-start with different times. Range 1 – 30 sec.

This value can be changed by pressing the arrow keys in the same
procedure as before described.
3. Delayed start of the Booster pumps after black- out
The pumps re-start with different times. Range 1 – 30 sec.

This value can be changed by pressing the arrow keys in the same
procedure as before described.
The function “delay start after black out “ can also be carried out,
by turning the main switch off and on.
ENTER to confirm each data input / to proceed to next menu
SHIFT This operator level is password protected and containes the delay times
+F4 for the alarms.
Textdisplay
Blbbla-bla
F5 F6 F7 F8
F1 F2 F3 F4
1. Pumps with drive
Type:
KF-42.BAA000242,
BG90S-4, 1.32 kW;
KF-42.BAA000242,
BG90L-2, 2.6 kW
Pos.: 1.1, 1.1.1, 1.2, 1.2.1;

1.3, 1.3.1, 1.4, 1.4.1

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Operating Instructions
Screw pumps
K Series
OIK 08B
02_02/2005 Edition
Table of contents
Operation
Startup
Filling the pump 31
Checking the direction of rotation 32
Commissioning the pump 33
Adjusting the overflow valve 33
Pump shutdown
Switching off the pump 35
Resuming pump operation
Restarting the pump 35
Servicing
Maintenance
Table of Contents
Maintenance requirement 37
Maintenance of seal
Maintaining the mechanical seal 38
General drawing of the pump with coupling and motor
General drawing 39
Replacing the coupling
Removing the coupling 40
Installing the coupling 43
General drawing of the pump
General drawing 47
Replacing the mechanical seal
Removing the mechanical seal 48
Installing the mechanical seal 51
Replacing the radial shaft seal Domsel type
Removing the radial shaft seal 56
Installing the radial shaft seal 58
Replacing the ball bearing
Removing ball bearings 63
Installing ball bearings 65
Replacing the set of screws
Removing the set of screws 69
Installing the set of screws 71
Assistance with problems
Troubleshooting
Faultfinding reference 75
Appendix
General drawings
Exploded view of pump with coupling and motor 81
Exploded view of the pump 82
Operation
Operation
Startup
Filling the pump
There are three possible ways to fill the pump:
• via the shut-off device on the suction side

• via the shut-off device on the pressure side
• via the vent holes
000017
3 2
<1> seal vent hole

<2> suction side vent hole
<3> pressure side vent hole
Fig. 1 Vent holes
Requirement:
• Pump securely attached

• Pump connection to the piping system is free of mechanical stress
• Pump motor is connected correctly to the electrical power supply
• Piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the
pump
WARNING!
Dry-running can damage pump equipment.
☞ Before you start it, make sure that the pump is full.
1. Open one of the vent holes on the pump casing.

2. If the pumped medium on the suction side is under inlet pressure, open the shut-off device on
the suction side and fill the pump. Turn the pump shaft or the fan impeller of the motor by hand
to speed up the filling process.
- or -
☞If there is already pumped medium available, open the shut-off device on the pressure side and
fill the pump. Turn the pump shaft or the fan impeller of the motor by hand to speed up the
filling process.
- or -
☞If there is no pumped medium at either the pressure or the suction side flange, fill the pump
via the vent hole. Turn the pump shaft or the fan impeller of the motor by hand to speed up the
filling process.
3. Fill the pump until pumped medium escapes at the vent hole.
4. Close the vent hole
5. Open vent hole of the seal <1> and wait until medium escapes.
6. Close vent hole of the seal.
31
Operation
Checking the direction of rotation
The direction of rotation and the direction of flow are indicated by arrows on the pump. The
direction of rotation of the motor gives the direction of rotation of the pump. That is to say, the fan
impeller of the motor must rotate in the direction in which the arrow on the pump is pointing to
indicate direction of rotation. Normally the direction of rotation of the pump is to the right
(clockwise), as seen from motor side.
<1> leakage
<2> arrow to indicate
direction of rotation
000018
3 3
<3> arrows to indicate

direction of flow
Fig. 2 Identifying direction of rotation and direction of flow
Requirement:
• Pump securely attached

• Pump connection to the piping system is stress free
• Pump motor is connected correctly to the electrical power supply
• Piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be flushed by the
pump
• Pump is full
WARNING!
☞ Turn the pump on (for max. 1 sec.) and then off again immediately (checking the direction of
rotation).
1. Switch on the power supply and then turn it off again immediately.
2. When the fan impeller of the motor moves slowly after switching off, compare the direction of
rotation of the fan impeller with the arrow indicating direction of rotation on the pump flange.
If the directions do not match, swap over two electrical connection phases. Repeat steps 1 and
2.
32
Operation
Commissioning the pump
Requirement:
• The ambient conditions correspond to the operating data, see "Operating data", page 4
• The pump is securely attached
• The pump is connected to the piping system without stress or strain
• The pump motor is connected correctly to the electrical power supply
• The piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the
pump
• The pump is full
• If there are shut-off devices in the suction and pressure pipes, they are open
WARNING!
☞ Before commissioning the pump, take note of these operating instructions.

☞ Before commissioning, make sure that the pump is full.
☞ If the pump does not deliver after 10–15 seconds, abort commissioning.
1. Switch on the pump.

The pump will deliver when the pressure on the pressure side of the pump rises or when a flow
indicator, which is available from the factory, responds.
2. If the pump does not deliver after 10–15 seconds of operation, abort commissioning, establish
the cause of the fault and only then continue the startup procedure. Follow the instructions in the
fault diagnosis charts, see "Faultfinding reference", page 75.
3. Run the pump for a few minutes to allow the piping system to vent fully.
The piping system is fully vented when there is a smooth operating noise and a pressure gauge
on the pressure side of the pump shows no more fluctuations.
Adjusting the overflow valve
2 3 4
<1> plugscrew
<2> setscrew
<3> spring
000004
<4> valve cone
Fig. 3 Mounting position of the overflow valve
If the delivery pipe on the pressure side of the pump is blocked, extremely high pressure can build
up which could possibly lead to the parts under pressure rupturing. An overflow valve is integrated
into KRAL pumps of the K series. The overflow valve prevents too high a pressure building up in
the pump. The overflow valve is set to 110 % of nominal pressure at the factory. This opening
pressure must not be exceeded in normal pump operation, otherwise the opening pressure of the
valve will have to be reset.
33
Operation
Requirement:
• Pump in operation
• Pressure gauge on the pressure side of the pump
Resource:
• Allen key for each pump size in accordance with the following table
Pump size DIN 908 Hexagon socket

K 5–20 R 1/4 " SW 6
K 32– 42 R 3/4 " SW 8
K 55–118 R 3/4 " SW 17
K 160–275 R 3/4 " SW 10
K 370– 450 R 3/4 " SW 17
K 550–660 R 3/4" SW 10
K 851–1301 R 3/4 " SW 17
K 1501–1701 R 3/4" SW 17
Tab. 1 Allen key widths for the various pump sizes
DANGER!
Risk of injury or fire, should pumped medium escape during overflow valve adjustment.
☞ Follow the safety instructions for handling hazardous liquids.
1. Check that the factory setting of the overflow valve meets the requirements of the installation. If
necessary, reset the safety valve.
2. Switch on the pump.
3. Open the plugscrew <1> of the overflow valve on the end cover.
4. Increase the delivery pressure step by step to check the opening pressure of the valve. Keep an
eye on the pressure gauge and make sure that the pressure stays within the operational limits.
When the overflow valve opening pressure is reached, the displayed pressure noticeably drops.
5. Turn the setscrew to adjust the opening pressure.
Turn it clockwise to increase the opening pressure.
Turn it anticlockwise to decrease the opening pressure.
6. Repeat steps 4 and 5 until the desired opening pressure is reached.
7. Tighten the plugscrew in the end cover again.
34
Operation
Pump shutdown
Switching off the pump
Requirement:
• Pump in operation
WARNING!
Pressurizing the pump while it is at a standstill may damage the pump seals.
☞ Make sure that while the pump is at a standstill, the pressure in the pump does not exceed
the inlet pressure during operation.
1. Disconnect the motor from the mains.

2. If there is no return valve fitted in the pressure pipe, close the shut-off device on the pressure
side.
Resuming pump operation

Restarting the pump
Requirement:
• A return valve incorporated in the suction pipe, if it is possible to drain the suction pipe when the
pump is at a standstill
• The requirements for commissioning are met, see "Commissioning the pump", page 33
WARNING!
☞ Before starting the pump, make sure that the pump is full.
☞ Switch on the pump.

Under the requirements mentioned above, the pump is ready for operation at any time.
35
Operation
36
Servicing
Servicing
Maintenance
Maintenance requirement
The service life of the pump is heavily dependent on the pump operating conditions. If the
operational limits are adhered to, see "Operating data", page 4, the pump will last for many years.
Symptoms of advanced wear in individual pump components can be detected in accordance with
the following table.
Findings Cause Remedy

Running noise increases Onset of bearing damage Replace bearing
Increased leakage Onset of seal damage Replace shaft seal
Abrasive components at the Non-volatile media Clean seal
seal
Increased shaft coupling play Advanced wear in the Replace intermediate ring
intermediate coupling ring
Drop in delivery rate and Advanced wear of screws and Replace screws and casing
pressure during constant casing
operating conditions
Tab. 1 Chart for testing the maintenance requirement
1. Check the pump regularly every four weeks, both by looking at it and by listening to it.
2. Check for symptoms of premature wear in accordance with the above chart and eliminate the
cause.
37
Servicing
Maintenance of seal
Maintaining the mechanical seal
When operating the pump with low volatile liquids (e.g. heavy fuel oil) the regular small amounts of
leakage may form solid deposits on the atmospheric side of the seal. During long-term operation
the increasing abrasive components may pile up to such an extent that a free drainage of the
leakage is not ensured anymore. As a result the leakage may contaminate and destroy the bearing.
To ensure a safe drain the permeability of the leakage vent holes has to be checked regularly.
Requirement:
• Pump dismantled, see "Removing the Pump", page 28
WARNING!
Bearing damage due to insufficient drainage of shaft seal leakage.
☞ Check permeability of leakage vent holes regularly.
1. If applicable, disassemble drainage pipe.

2. Check permeability of leakage pipe: e.g. observe
drainage of a small amount of liquid poured into
the pipe
- or -
☞ check by visual inspection
- or -
☞ introduce plug of soft material (wood, polymer
etc.).
3. Clean drainage pipe and/or vent hole, if not per-
meable.
4. Re-assemble leakage pipe, if applicable.
38
Servicing
General drawing of the pump with

coupling and motor
General drawing
K6
K5 K7
K4
K3
K2
K1
K8
K9
000098
K10
K11
Fig. 1 Exploded view of a K-pump with coupling and motor
<K1>pump <K7>motor
<K2>socket screws <K8>hexagon screws
<K3>distance sleeve <K9>socket screws
<K4>pump side coupling part <K10>pump bracket
<K5>coupling intermediate ring <K11>pump pedestal
<K6>motor side coupling part
39
Servicing
Replacing the coupling

Removing the coupling
Requirement:
1. Before starting to disassemble the aggregate use

suitable covers to protect the pump internals
from dirt and solid bodies.
2. Remove hexagon screws <K8> which connect

motor <K7> and pump bracket <K10>.
3. Carefully lift pump <K1> with pump bracket

<K10> off the motor <K7>.
40
Servicing
4. Open fixation screw of the motor side coupling

part <K6>.
5. Remove coupling part <K6> with suitable extrac-

tor.
6. Open socket screws <K2> which connect pump

<K1> and pump bracket <K10>.
7. Lift the pump bracket <K10> together with pump

pedestal <K11> off the pump.
41
Servicing
8. Remove fixation screw of the pump side coupling

part <K4>.
9. Take off the coupling part <K4> by means of suit-

able levers.
10. Take off the coupling distance sleeve <K3> from

the shaft.
42
Servicing
Installing the coupling
Requirement
• Replacement coupling available
1. Slide distance sleeve of the coupling <K3> onto

the pump shaft until it is flush with the bearing
circlip.
2. Slide pump side coupling part <K4> onto the

pump shaft until it is flush with the distance
sleeve <K3>. Heating up the coupling to 80°-100°
C facilitates assembly.
3. Tighten fixation screw of the coupling part <K4>.
43
Servicing
4. Put the pump bracket <K10> with pump pedestal

<K11> onto the pump.
5. Tighten connecting screws <K2> of pump and

pump bracket.
6. Measure distance X between front face of cou-

pling part and connecting surface of pump brack-
et.
7. Drive motor side coupling part <K6> onto shaft

end of the motor with light strokes of a soft ham-
mer. Heating up the coupling to 80° - 100°C facil-
itates assembly.
44
Servicing
8. Check distance between front face of coupling

gears and connecting surface of motor flange. Ad-
just to the value x - c (see Tab. 2, page 45a).
9. Insert elastic coupling intermediate ring <K5> and

tighten fixation screw at the coupling part <K6>.
10. Lift pump with pump bracket onto the motor.
11. Turn pump slightly until the gears of the pump

side coupling part <K4> will engage properly with
the gears of the coupling intermediate ring <K5>.
45
Aligning and checking the shaft coupling
Requirement:
• Pump, shaft coupling and motor fitted by the customer
<a> lateral offset

<b> angular offset
<c> linear offset
Fig. 4 Measuring points for coupling alignment tolerances
Coupling diameter Lateral offset <a> Angular offset <b> Linear offset <c>
[mm] max. [mm] max. [°] min. [mm] max. [mm]
40 0,2 0,9 2 3
55 0,2 0,9 2 3,5
65 0,25 0,9 2,5 4
80 0,3 1,0 3 4,5
95 0,3 1,0 3 5
120 0,4 1,1 4 6
135 0,4 1,2 4,5 7
160 0,5 1,2 5 8
Tab. 2 Limits for shaft coupling alignment
DANGER!
If the shaft coupling is not aligned correctly, this will cause noise, vibration and damage to the
bearing.
☞ Check the alignment of the coupling.
45a
Servicing
12. Tighten connecting screws <K8> of motor and

pump bracket.
13. Remove protective covers only just before con-

necting the pump unit to the pipe system.
46
Servicing
General drawing of the pump

General drawing
15
11 12 14
13 16 17
8 10
18
7 9
20 19
6
21
22
5
4 23
3
2
25 24
28
1
29 26
43
44 33
42 27
36
45 41
30
46
31
32
35 34
37
38
39
40 000143
Fig. 2 Exploded view of a K-pump
<1>socket screws <13>flat gasket <25>straight pin <36>spacer

<2>plug screw <14>flange cover <26>circlip * <37>circlip
<3>flat gasket <15>plug screw * <27>radial shaft seal * <38>balancing cylinder
<4>end cover <16>flat gasket * <28>flat gasket <39>main screw
<5>flat gasket <17>circlip <29>plug screw <40>idle screws
<6>pump casing <18>support ring <30>o-ring <41>key
<7>flat gasket <19>circlip <31>counter ring <42>plug screw
<8>plug screw <20>ball bearing <32>rotating ring <43>flat gasket
<9>flat gasket <21>socket screws <33>o-ring <44>valve cone
<10>flat gasket <22>dowel pin <34>thrust ring <45>spring
<11>plug screw <23>flat gasket * <35>conical spring <46>adjusting screw
<12>plug screw <24>plug screw *
* only for version radial shaft seal
47
Servicing
Replacing the mechanical seal

Removing the mechanical seal
Requirement:
1. Unscrew the four socket screws <21> on the

flange cover <14>.
2. Loosen the flange cover <14> with gentle "re-

bound" blows.
3. Take out the withdrawable unit comprising the

main screw <39>, the bearing <17>–<20>, the
seal <30>–<35> and the flange cover <14> from
the pump casing <6>.
48
Servicing
4. Detach the circlip <17>.
5. Remove the support ring <18>.
6. Expel the main screw <39> with the mechanical

seal <30>–<35> by gently driving it out of the
bearing <20> with a soft hammer.
7. Press the counter ring <31> of the mechanical

seal cautiously out of the flange cover <14> by
using a soft arbor.
49
Servicing
8. Remove o-ring <30> from flange cover <14> , if

it has not been removed together with the coun-
ter ring <31>.
9. Gently turn the rotating ring <32> with conical

spring <35>, thrust ring <34> and o-ring <33>, to
push them down from the main screw <39>.
10. Remove the spacer <36> from the main screw.
50
Servicing
Installing the mechanical seal
Requirement:
• Replacement seal available
• New flat gasket available
1. Carefully remove the remains of the flat gasket

<9> from the flange cover <14> and pump casing
<6>.
2. Carefully clean the supporting surface of the o-

ring in the flange cover <14>.
3. Evenly grease-in the counter ring <31> of the re-

placement part with the drawn-on o-ring <30>.
51
Servicing
4. Insert the counter ring <31> with drawn-on o-ring

<30>into the flange cover <14>. Make sure that
the dowel pin <22> for the locking element is sit-
ting in the notch of the counter ring.
5. Press the counter ring <31> flush into the flange

cover <14> by using a soft arbor.
6. Carefully clean and grease the main screw <39>

in the region of the mechanical seal.
7. Position the spacer <36>, carefully turn the coni-

cal spring <35>, the thrust ring <34>, and the ro-
tating ring <32> with the o-ring <33> of the
replacement part to push them on to the main
screw <39>. Make sure that the o-ring is not
damaged by being pushed over the shoulders of
the shaft.
52
Servicing
8. Carefully clean the slide surfaces of rotating ring

<32> and counter ring <31> with cleaning spirit.
9. Administer a drop of resin-free lubricating oil to

the slide surfaces of rotating ring <32> and coun-
ter ring <31>. Do not touch the slide surfaces
thereafter.
10. Press-in the main screw <39> with the replace-

ment seal parts pushed on, until it stops in the
ball bearing in the flange cover.
11. Slide-on the support ring <18>.
53
Servicing
12. To fix the main screw <39>, fit the circlip <17>.
13. Place the new flat gasket <9> onto the pump cas-
ing <6>. Carefully grease the sealing surfaces.
14. Turn the preassembled unit until the vent hole in

the flange cover <14> is in the same position as
the associated hole in the pump casing <6>. Take
care of position of straight pin <25>.
15. Push the preassembled unit comprising the

flange cover <14> and the main screw <39> into
the pump casing <6>, until the main screw en-
gages in the idle screws <40>. Turn the main
screw while doing this.
54
Servicing
16. Tighten the four socket screws <21> on the

flange cover <14>.
55
Servicing
Replacing the radial shaft seal Domsel

type
Removing the radial shaft seal
Requirement:

flange cover <14>.

bound" blows.

main screw <39>, the bearing <17>-<20>, the
seal and the flange cover <14> from the pump
casing <6>.
56
Servicing
6. Expel the main screw <39> by gently driving it

out of the bearing <20> with a soft hammer.
7. Remove the circlip <26>.
57
Servicing
8. Remove the radial shaft seal <27>. If manual dis-

mantling is impossible, use an appropriate arbor.
Normally dismantling destroys the shaft seal.
Installing the radial shaft seal
Requirement:
• Replacement seal available

<6>.
2. Apply thread sealant Loctite 572 (or according al-

ternate product) to the seat of the radial shaft seal
in the flange cover <14>. The fluid acts as a lubri-
cant at assembly, and as an anti-twist stop after
hardening.
58
Servicing
3. Prepare a suitable arbor for the assembly of the

radial shaft seal. The arbor has to lie flush on the
support surface of the seal and must not have any
sharp edges in the area of the sealing lip.
4. Pay attention to the mounting direction of the ra-

dial shaft seal.
5. Carefully press-in the radial shaft seal <27> by us-

ing the arbor. At excessive resistance apply addi-
tional thread sealant for lubrication.
6. Insert the circlip <26> for the axial securing of the

radial shaft seal <27>.
59
Servicing
7. Grease-in the gap of the radial shaft seal <27>

with MoS2-paste (type Fenkart T4 or the like).
8. Before mounting the main screw <39> slide-on a

suitable sleeve to protect the radial shaft seal
<27> against possible damages caused by key or
shaft shoulder.
9. Insert the main screw <39> into the flange cover

<14> with premounted radial shaft seal <27>.
10. Remove the protective sleeve.
60
Servicing
11. Insert the ball bearing <20>.
12. Press-in the ball bearing <20> into the flange cov-
er <14>.
13. Slide-on the support ring <18> and mount the cir-
clip <17> to fix the main screw.
61
Servicing

the flange cover is in the same position as the as-
sociated hole in the pump casing. Take care of po-
sition of straight pin <25>.


flange cover.
62
Servicing
Replacing the ball bearing

Removing ball bearings
Requirement:

flange cover <14>.

bound" blows.

main screw <39>, the bearing <17>–<20>, the
seal and the flange cover <14> from the pump
casing <6>.
63
Servicing

7. Loosen the circlip <19> in the flange cover <14>.
64
Servicing
8. Use an extractor to pull the bearing <20> out of

the flange cover <14>.
Installing ball bearings
Requirement:
• Replacement bearing available

<6>.
2. Press-in the ball bearing <20> into the flange cov-

er <14>.
65
Servicing
3. To attach the ball bearing <20> in the flange cov-

er <14>, fit the circlip <19>.


thereafter.
6. Press-in the main screw <39> with the seal parts

pushed on, until it stops in the ball bearing in the
flange cover <14>.
66
Servicing
9. Place the new flat gasket <11> onto the pump

casing <14>. Carefully grease the sealing surfac-
es.

67
Servicing
11. Push the preassembled unit comprising flange

cover <14> and the main screw <39> into the
pump casing <6>, until the main screw engages
in the idle screws <40>. Turn the main screw
while doing this.

flange cover <14>.
68
Servicing
Replacing the set of screws

Removing the set of screws
Requirement:

flange cover <14>.

bound" blows.
3. Take out the withdrawable unit comprising main

screw <39>, the bearing <17>–<20>, the seal
and the flange cover <14> from the pump casing
<6>.
69
Servicing

7. Gently turn the rotating ring <32> with conical

spring <35>, thrust ring <34> and o-ring <33> to
push them down from the main screw <39>.
70
Servicing
8. Remove the spacer <36> from the main screw .
9. Remove the idle screws <40> from the pump

casing <6>.
Installing the set of screws
Requirement:
• Replacement set of screws available

<9> from the flange cover <14> and the pump
casing <6>.
71
Servicing
2. Insert the new idle screws <40> into the pump

casing <6>.
3. Carefully clean and grease the new main screw

<39> in the region of the shaft seal.
4. Fit the spacer <36>. Carefully push conical spring

<35>, thrust ring <34> and rotating ring <32>
with o-ring <33> of the mecahnical seal onto the
new main screw <39> by gently turning them.
Make sure that the o-ring is not damaged by being
pushed over the shoulders of the shaft.

72
Servicing

thereafter.
7. Press-in the main screw <39> with the seal parts

pushed on, until it stops in the ball bearing <20>
in the flange cover <14>.
73
Servicing
11. Turn the preaseembled unit until the vent hole in



flange cover <14>.
74

Troubleshooting
Faultfinding reference
Malfunctions can have different causes. The following table lists the symptoms of a fault, the
possible causes and measures for elimination.
Findings Cause and remedy

No pump suction Pump suction pipe closed
☞ Check shut-off devices in the suction pipe and open it, if
necessary.
Suction valve or pipe obstructed
☞ Check for clear passage through the suction valve and pipe.
Level of liquid in the intake container too low
☞ Top-up the pumped medium.
Dirty filter
☞ Clean the filter.
Pump intake capacity reduced by inadequate wetting
☞ Fill pump with medium.
Incorrect pump rotation direction
☞ Make the electrical connection such that the direction of pump
rotation matches that of the arrow on the flange cover.
Leaking suction pipe or shaft seal
☞ Check suction pipe or shaft seal for leaks. Pay particular
attention to leakage at valves and connection points. If
necessary, replace parts.
Suction head too high
☞ Reduce difference of level
- or -
☞reduce pipe length
- or -
☞increase pipe diameter
- or -
☞heat the medium to reduce viscosity
- or -
☞fit a suction filter with greater mesh width. Make sure that
the permissible mesh width is not exceeded, see Tab. 1,
page 26.
Pump does not vent
☞ Vent the pressure pipe at the highest point.
75

Delivery rate too low Differential pressure at the pump too high
☞ Check the installation and reduce the differential pressure.
Viscosity of the pumped medium too high
☞ Raise the temperature of the medium
- or -
☞reduce the rotation speed.
Viscosity of the pumped medium too low
☞ Lower the temperature of the medium
- or -
☞increase the rotation speed
Dirty filter
- or -
- or -
- or -
- or -
page 26.
Motor running at wrong voltage or frequency
1. Make sure that the motor voltage and frequency match the
operating voltage.
2. Compare the speed of the motor with the pump nameplate. If
the data does not match, adjust the speed of the motor.
Airlock or gas in the medium
1. Test the piping system for air admission and if necessary,
replace parts.
2. Reduce the suction head
- or -
☞increase the inlet pressure.
Overflow valve opens during normal operation
☞ Set opening pressure above value of operating pressure.
Overflow valve leaking
☞ Clean overflow valve and if necessary, re-seat.
Advanced wear of rotating pump components
☞ Check set of screws and casing and replace if necessary.
76

Pump runs noisily Dirty filter
- or -
- or -
- or -
- or -
☞fit suction filter with greater mesh width. Make sure that the
permissible mesh width is not exceeded, see Tab. 1, page
26.
Viscosity of pumped medium too high
- or -
☞reduce the rotation speed
replace parts.
- or -
Inadequate alignment of shaft coupling
☞ Align the shaft coupling correctly, see "Aligning and checking
the shaft coupling", page 27.
Pump deflected
1. Support the weight of the pipeline.
2. Loosen pipeline connections and assemble stress free, see
"Installing the pump", page 26.
Resonance in the installation
☞ Provide a flexible bearing arrangement for the unit
- or -
☞make the connections with hoses.
Speed of flow in suction or pressure pipe too high
1. Set the flow speed in the suction pipe so that it does not
exceed 1 m/s.
2. Set the flow speed in the pressure pipe so that it does not
exceed 3 m/s.
Ball bearing damaged
☞ Replace the ball bearing, see "Removing ball bearings", page
63.
77

Motor overload Motor running at wrong voltage or frequency
1. Make sure that the motor voltage and frequency match the
operating voltage.
2. Compare the speed of the motor with the pump nameplate. If
the data does not match, adjust the speed of the motor.
Differential pressure too high
☞ Check the installation and reduce the differential pressure.
High viscosity of pumped medium
- or -
Lack of lubrication or foreign bodies have caused superficial
damage to rotating pump components
☞ Check the set of screws and the casing and replace if
necessary.
Damaged rolling bearing
☞ Replace the rolling bearing, see "Removing ball bearings", page
63.
Uneven pump capacity Dirty filter
- or -
- or -
- or -
- or -
page 26.
Viscosity of the pumped medium is too high
- or -
replace parts.
- or -
Overflow valve leaks
☞ Clean the overflow valve and if necessary, re-seat.
78

Leaking shaft seal Dry running has damaged the shaft seal
☞ Replace the shaft seal, see "Removing the mechanical seal",
page 48. When starting up the pump, pay attention to venting.
Inlet pressure too high
☞ Reduce the inlet pressure at the installation end.
Thermal or chemical loading of elastomer seals exceeded
1. Check the maximum operating temperature.
2. Check the resistance of the elastomer with regard to the
pumped medium.
Cold start when delivering high-viscosity media
☞ Install pump heating.
Seal overload during heating process
☞ To prevent thermal expansion of the media causing a buildup
of pressure, open the pressure or suction side shut-off
devices.
Leaking return valve causes seal overload when pump is at a
standstill
☞ Clean the return valve and if necessary, replace it.
Advanced wear of sealing surfaces
☞ Replace the seal and if necessary, check the pumped medium
for abrasive content.
Pump is stuck Foreign bodies in the pump
☞ Dismantle the pump and clean it.
☞ Smooth the superficial damage to the casing and the rotating
parts with an oilstone and if necessary, replace the set of
screws and/or the casing.
Differential pressure is too high and has overloaded the sleeve
bearing
☞ Dismantle the pump.
☞ Reduce the differential pressure.
Viscosity is too low and has overloaded the sleeve bearing
☞ Increase the viscosity, for example by reducing the operating
temperature.
Dry running has damaged the pump
☞ When resuming operation, take action to prevent dry running,
see "Resuming pump operation", page 35.
Tab. 1 Fault diagnosis chart
79
80
Appendix
Appendix
General drawings
Exploded view of pump with coupling and motor
K6
K5 K7
K4
K3
K2
K1
K8
K9
000098
K10
K11
Fig. 1 Exploded view of a K-pump with coupling and motor
Item no. Part Spare part no. Item no. Part Spare part no.
<K1> pump 001 <K7> motor 529
<K2> socket screws 914,1 <K8> hexagon screws 900,1
<K3> distance sleeve 039 <K9> socket screws 914,2
<K4> pumpside coupling part 52,1 <K10> pump bracket 180
<K5> coupling intermediate ring 525 <K11> pump pedestal 225
<K6> motorside coupling part 52,2
81
Appendix
Exploded view of the pump
15
11 12 14
13 16 17
8 10
18
7 9
20 19
6
21
22
5
4 23
3
2
25 24
28
1
29 26
38
39 37
31
27
40 36
41
30
32
33
34
35
Fig. 2 Exploded view of a K-pump 000099
<1> socket screws 914,2 <22> dowel pin 859
<2> plug screw 165,1 <23> flat gasket* 729,3
<3> flat gasket 729,1 <24> plug screw* 165,3
<4> end cover 070 <25> straight pin 879
<5> flat gasket 729,4 <26> circlip* 471,4
<6> pump casing 131 <27> radial shaft seal* 745
<7> flat gasket 729,2 <28> flat gasket 729,2
<8> plug screw 165,2 <29> plug screw 165,2
<9> flat gasket 729,5 <30> mechanical seal 457
<10> flat gasket 729,2 <31> spacer 062
<11> plug screw 165,2 <32> circlip 471,1
<12> plug screw 165,3 <33> balancing cylinder 042
<13> flat gasket 729,3 <34> main screw 661
<14> flange cover 074 <35> idle screws
82
Appendix
<15> plug screw* 165,3 <36> key 866
<16> flat gasket* 729,3 <37> plug screw 165,2
<17> circlip 471,2 <38> flat gasket 729,2
<18> support ring 056 <39> valve cone 305
<19> circlip 471,3 <40> spring 501
<20> ball bearing 817 <41> adjusting screw 164
<21> socket screws 914,1
*only for version radial shaft seal
Tab. 1 Spare part numbers
83
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FOR ELECTRIC MOTORS ENGLISH
INSTRUCCIONES PARA LA INSTALACIÓN Y

MANTENIMIENTO DE MOTORES ELÉCTRICOS
BETRIEBS - UND WARTUNGSANLEITUNGEN

FÜR ELEKTROMOTOREN
INSTRUCTIONS POUR INSTALLATION ET

MANUTENTION DE MOTEURS ÉLECTRIQUES
ISTRUZIONI DUSO E MANUTENZIONE

PER MOTORI ELETTRICI
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNING
FOR ELEKTRISKE MOTORER
INSTALLATIONS- OCH UNDERHÅLLSINSTRUKTIONER

FÖR ELEK
0280.1400
ENGLISH
In case the motors are stored for more than

READ CAREFULLY THIS MANUAL
two years, the bearings must be replaced or the
ENGLISH
BEFORE INSTALLING THE MOTOR
lubrication grease must be totally removed after
cleaning.
RECEIVING CHECK Single phase motors when kept in stock
for 2 years or more must have their capacitors
Check if any damage has occured during
replaced (if any).
transportation.
We recommend to turn the shaft (by hands)
üCheck nameplate data.
at least once a month, and to measure the
üRemove shaft locking device (if any) before
insulation resistance before installing it, in cases
operating the motor.
of motors stored for more than 6 months or when
üTurn the shaft with the hand to make sure it
subject to high humidity areas.
is turning freely. If motor is fitted with space heaters, these
HANDLING AND TRANSPORTATION should be switched on.
1 - General Insulation Resistance Check

MOTORS MUST NOT BE LIFTED BY Measure the insulation resistance before
THE SHAFT, BUT BY THE EYEBOLTS operating the motor and/or when there is any
sign of humidity in the winding.
Lifting devices, when supplied, are
designed only to support the motor. If the motor The resistance measured at 25ºC must be:
has two lifting devices then a double chain must
be used to lift it. Ri ≥ (20 x U) / (1000 + 2P) [MΩ]
Lifting and lowering must be done gently (measured with a MEGGER at 500 V d.c.)
without any shocks, otherwise the bearings can where U = voltage (V); P = power (kW).
get damaged.
If the insulation resistance is less than 2
DURING TRANSPORTATION,
megaohms, the winding must be dried
MOTORS FITTED WITH ROLLER OR
according to the following:
ANGULAR CONTACT BEARINGS
Warm it up inside an oven at a minimum
ARE PROTECTED AGAINST
temperature of 80ºC increasing 5ºC every hour
BEARING DAMAGES WITH A
until 105ºC, remaining under this temperature
SHAFT LOCKING DEVICE.
for at least one hour.
Check if the stator insulation resistance
THIS LOCKING DEVICE MUST BE
remains constant within the accepted values. If
USED ON ANY FURTHER MOTOR
not, stator must be reimpregnated.
TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE. INSTALLATION
STORAGE 1 - Safety
If motors are not immediately installed, All personnel involved with electrical
they must be stored in dry places, free of installations, either handling, lifting, operation
dust, vibrations, gases, corrosive smokes, or maintenance must be well informed and
under constant temperature and in normal updated concerning safety standards and
position free from other objects. principles that govern the work and carefully
Motor storage temperature must remain follow them.
between 5ºC to 60ºC, with relative humidity not We strongly recommend that these jobs
exceeding 50%. are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC designed in such a way to stop any vibration
MOTORS ARE SWITCHED OFF originated from resonance.
BEFORE STARTING ANY
MAINTENANCE SERVICE. 4 - Drain Holes
Motors must be protected against acci- Make sure the drains are placed in the
dental starts. lower part of the motor when the mounting
When performing any maintenance configuration differs from that specified on the
service, disconnect the motor from the power motor purchase order.
supply. Make sure all accessories have been
switched off and disconnected. 5 - Balancing
In order to prevent from penetrating dust
and/or water into the terminal box, cable glands THE MOTORS ARE DYNAMICALLY
or threaded pipe in the lead holes must be BALANCED WITH HALF KEY, AT NO
installed. LOAD AND UNCOUPLED.
Do not change the regulation of the
protecting devices to avoid damaging. Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
2 - Operating Conditions with half key before installation.
Use always appropriate tools for installation and
Electric motors, in general, are designed removal.
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0ºC 6 - Alignment
and 40ºC. Any variation is stated on the
ALIGN THE SHAFT ENDS AND
nameplate.
USE FLEXIBLE COUPLING,
COMPARE THE CURRENT, VOLTAGE, WHENEVER POSSIBLE.
FREQUENCY, SPEED, OUTPUT AND
Ensure that the motor mounting devices
OTHER VALUES DEMANDED BY THE
do not allow modifications on the alignment and
APPLICATION WITH THE DATA GIVEN
further damages to the bearings.
ON THE NAMEPLATE.
When assembling a half-coupling, be sure
Motors supplied for hazardous locations to use suitable equipment and tools to protect
must be installed in areas that comply with that the bearings.
specified on the motor nameplate. Suitable assembly of half-coupling:
Check that clearance Y is less than
KEEP AIR INLET AND OUTLET FREE 0.05 mm and that the difference X1 to X2 is less
AND CLEAN. THE AIR BLOWN OUT than 0.05 mm, as well.
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
Motors provided with feet must be installed 3mm minimum
on solid foundations to avoid excessive Figure and alignment tolerances
vibrations.
The purchaser is fully responsible for the 7 - Belt Drive
foundation.
Metal parts must be painted to avoid When using pulley or belt coupling, the
corrosion. following must be observed:
The foundation must be uniform and suf- Belts must be tighten just enough to avoid
ficiently tough to support any schock. It must be slippage when running, according to the
specifications stated on the belt supplier Make sure to use the correct cable
recommendation. dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
ENGLISH
Excessive tension on the pulleys will BEFORE ENERGIZING THE
damage the bearings and lead to a TERMINALS, CHECK IF THE
probable shaft rupture. GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
8 - Connection AGAINST ACCIDENT RISKS.
WARNING: When the motor is supplied with

Voltage may be connected at standstill protective or monitor temperature device such
inside the terminal box for heating elements or as thermostats, thermistors, termal protector, etc,
direct winding heating. connect their terminals to the corresponding
devices on the control panel.
WARNING:
The capacitor on single-phase motors 10 - Start-Up
can retain a charge which appears across the
THE KEY MUST BE FASTENED OR
motor terminals, even when the motor has
REMOVED BEFORE STARTING THE
reached standstill.
MOTOR.
A WRONG CONNECTION CAN a) The motor must start and operate
BURN THE MOTOR. smoothly. In case this does not occur, turn it off
and check the connections and the mounting
before starting it again.
Voltage and connection are indicated on
b) If there is excessive vibration, check if
the nameplate. The acceptable voltage the fastening screws are correctly fastened.
variation is ±10%; the acceptable frequency Check also if the vibration comes from a
variation is ±5% and the total acceptable neighbour machine. Periodical vibration checks
variation is ± 10%. must be done.
c) Run the motor under rated load for a
9 - Starting Methods short period of time and compare if the running
current is equal to that stamped on the
The motor is rather started through direct nameplate.
starting. In case this is not possible, use
compatible methods to the motor load and MAINTENANCE
voltage.
The rotation direction is clockwise if the WARNING:
motor is viewed from DE side and if the SAFETY CHECK LIST
phases are connected according to the
sequence L1, L2, L3. 1 - General Inspection
To change the rotation direction, inter-
change two of the connecting leads. üCheck the motor periodically.
üKeep the motor clean and assure free air flow.
THE CONNECTION TO THE POWER üCheck the seals or V Ring and replace them, if
SUPPLY MUST BE DONE BY required.
QUALIFIED PERSONNEL AND WITH üCheck the connections as well as supporting
FULL ATTENTION TO ASSURE A SAFE screws.
AND PERMANENT CONNECTION. üCheck the bearings and observe: Any excessive
AFTER CONNECTING THE MOTOR, noise, vibration, bearing temperature and grease
CHECK FOR ANY STRANGE BODY condition.
INSIDE THE TERMINAL BOX. THE üWhen a change, under normal conditions, is
CABLE INLETS NOT IN USE MUST BE detected, check the motor and replace the
CLOSED. required parts.
The frequency of the inspections depends 2 - Machines Fitted with Grease Nipples
on the motor type and on the application
conditions. It is strongly recommended to grease the
machine while running. This allows the grease
LUBRICATION renewal in the bearing housing. When this is
not possible due to turning parts by the grease
FOLLOW THE REGREASING device (pulleys, bushing, etc) that offer some
INTERVALS. THIS IS FUNDAMENTAL risk to the physical integrity of the operator,
FOR PROPER MOTOR OPERATION. proceed as follows:
üClean the area near the grease nipple.
1 - Machines without Grease Nipples üPut approximately half of the total grease and
run the motor for 1 minute at full speed.
Motors up to frame 200 are normally fitted Then turn off the motor and insert the rest of the
without grease nipples. In these cases the grease.
regreasing shall be done at the preventive üThe injection of all the grease with the motor in
maintenance job observing the following standstill can make the grease penetrate into the
aspects: motor, through the inner seal of the bearing
housing.
üDisassemble carefully the motors.
üTake all the grease out. FOR LUBRICATION USE ONLY
üWash the bearing with querosene or diesel. MANUAL GREASE GUN.
üRegrease the bearing immediately.
RELUBRICATION INTERVALS
TABLE 1 - BALL BEARINGS - Series 62/63

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
Serie 62
Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 63
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - Series NU 3

Relubrication intervals (running hours horizontal position)
II pole IV pole VI pole VIII pole X pole XII pole Grease
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Note: The stator grips must be applied over the
üThe ZZ bearings from 6201 to 6307 do not side face of the inner ring to be disassembled or
require relubrication as its life time is about over an adjacent part.
20,000 hours. It is essential that bearings assembly be
üTables 1 and 2 are intended for the lubrication
ENGLISH
done under cleanning conditions to ensure
period under bearing temperature of 70°C (for good operation and to avoid damages. New
bearings up to 6312 and NU 312) and bearings shall only be taken out from their cases
temperature of 85°C (for bearings 6314 and NU when assembling them.
314 and larger). Before installing a new bearing it is
üFor each 15°C of temperature rise, the required to check the shaft fitting for any sharp
relubrication period is reduced by half. edge or strike signals.
üThe relubrication periods given above are For bearing assembly warm their inner
for those cases applying Polyrex® EM grease. parts withsuitable equipment - inductive pocess
ü When motors are used on the vertical - or use suitable tools.
position, their relubrication interval is reduced SPARE PARTS
by half if compared to horizontal position
motors. When ordering spare parts, please specify
WE RECOMENDED TO USE BALL the full type designation and product code as
BEARINGS FOR MOTORS DIRECTLY stated on the motor nameplate. Please also
inform the motor serial number stated on the
COUPLED TO THE LOAD. nameplate.
WARNING: MOTORS FOR HAZARDOUS
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING LOCATIONS
RESULTING IN COMPLETE Besides the recommendations given
DAMARGE. previously, these ones must be also followed:
Compatibility of Polyrex® EM grease THE SPECIFICATION OF THE MOTOR

with other types of grease: INSTALLATION PLACE IS FOR
CUSTOMER’S RESPONSIBILITY,
Containing polyurea thickener and mineral WHO WILL ALSO DETERMINE THE
oil, the Polyrex® EM grease is compatible with ENVIRONMENT CHARACTERISTICS.
other types of grease that contain:
üLithium base or complex of lithium or polyurea Motors for hazardous locations are
and highly refined mineral oil. manufactured according to specific standards
üInhibitor additive against corrosion, rust and for such environments and they are certified by
anti-oxidant additive. worldwide certifying entities.
Notes: 1 - Installation
üAlthough Polyrex® EM is compatible with types
of grease given above, we do not recommended The complete installation must follow
to mix it with any other greases. procedures given by the local legislation in effect.
ü If you intend to use a type of grease different
than those recommended above , first contact THE INSTALLATION OF HAZARDOUS
KUWO. LOCATION MOTORS MUST BE
üOn applications (with high or low temperatures, CARRIED OUT BY SKILLED PEOPLE,
speed variation, etc), the type of grease and
relubrification interval are given on an additional AND THE THERMAL PROTECTION
nameplate attached to the motor. MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
THE USE OF STANDARD MOTORS
MOTOR, OPERATING AT THE RATED
IN SPECIFIC AREAS OR SPECIAL
CURRENT.
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE 2 - Maintenance
MANUFACTURER OR KUWO
Maintenance must be carried out by repair
shops authorized by KUWO.
DISASSEMBLY AND ASSEMBLY Repair shops and people without KUWO’s
authorization who will perform any service on
Disassembly and assembly must be done hazardous location motors will be fully
by qualified personnel using only suitable tools responsible for such service as well as for any
and appropriated methods. consequential damage.
üLower efficiency.
ANY ELECTRICAL OR MECHANICAL
üHigher vibration.
MODIFICATION MADE ON
üHigher noise level.
HAZARDOUS LOCATION MOTORS üHigher rated current.
WILL VOID THE CERTIFICATION. ü Higher temperature rise.
When performing maintenance, üReduced motor insulation.
installation or relubrication, follow these üReduced bearing life.
instructions:
1- Standard Motors
üCheck if all components are free of edges,
knocks or dirt.
üMake sure all parts are in perfect conditions. üVoltages lower than 440V do not require filter.
üLubricate the surfaces of the endshield fittings üVoltages equal or higher than 440V or lower
with protective oil to make the assembly easier. than 575V require filter for motor power supply
üUse only rubber hammer to fit the parts. cables longer than 20 meters.
üCheck for correct bolts tightening. üVoltages equal or higher than 575V require
üUse clearance calibrator for correct T-box fitting filter for any size of power supply cables.
(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR IF SUCH RECOMMENDATIONS ARE
WORN PARTS. REPLACE THEM BY NOT FOLLOWED ACCORDINGLY,
NEW ONES SUPPLIED BY THE MOTOR WARRANTY WILL BE VOID.
FACTORY.
2- Inverter Duty Motors:
MOTORS DRIVEN BY VFD üCheck power supply voltage of the forced
Applications using VFD´s without filter cooling set.
can affect motor performance as follows: üFilters are not required.
WARRANTY TERMS
We warrant our products against defects in This warranty does not include disassembly
workmanship and materials for twelve (12) services at the purchaser facilities,
months from the invoice date issued by the transportation costs with product, tickets,
factory, authorized distributor or agent limited accomodation and meals for technical personnel
to eighteen (18) months from manufacturing date when requested by the customer.
independent of installation date as long as the The warranty service will be only carried out at
following items are fulfilled accordingly: KUWO Authorized Repair Shops or at our
facilities.
- Proper transportation, handling and storage;
- Correct installation based on the specified Components whose useful life, under normal
ambient conditions and free of corrosive use, is shorter than the warranty period are not
gases; covered by these warranty terms.
- Operation under motor capacity limits; The repair and/or replacement of parts or
- Observation of the periodical maintenance components, when effected by KUWO and/or any
services; KUWO Authorized Repair Shop, will not give
- Repair and/or replacement effected only by warranty extension.
personnel duly authorized in writing by KUWO;
- The failed product be available to the supplier This constitutes KUWO’s only warranty in
and/or repair shop for a required period to connection with this sale and the company will
detect the cause of the failure and have no obligation or liability whatsoever to
corresponding repair; people, third parties, other equipment or
- Immediate notice by the purchaser about installations, including without limitation, any
failures accured and that these are accepted claims for consequential damages or labor costs.
by KUWO as manufacturing defects.
2. Filter
ATTENTION!
Valid for all filter with heating chamber (heating connection):
At the first start up of trace heating the heat transfer cement
connecting the heating chamber to the filter may get splits or
cracks due to extension.
This will not lead to a leakage of heating medium.
Type: 2.04.5.6.110.210,
6.62 Gr.04
Pos.: 2.1, 2.2

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
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)
ERSATZTEILLISTE TYP 2.04.5
SPARE PART LIST LISTE DES PIECES DE RECHANGE

Typenschlüssel:
2.04.5. =Doppelfilter duplex filter Filtre double
G . =Gehäusedurchmesser cabin diameter diamètre du corps
Q . = Filtereinsatzlänge length of the filter element longueur du panier
DN .= Anschlußflansche connection flanges brides désirées
Pos Bezeichnung
. Designation DN 25 St. DN 32 St. DN 40 St. DN 50 St. DN 65 St. DN 80 St.
Nr. Designation
Verschlußschraube
2 screw plug 2000188 2 2000188 2 2000188 2 2000188 2 2000188 2 2000188 2
vis
Dichtung
3 gasket 3270003 2 3270003 2 3270003 2 3270003 2 3270003 2 3270003 2
joint
Verschlußschraube
4 screw plug 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
vis
Dichtung
5 gasket 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
joint
Verschlußschraube
6 screw plug 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
vis
Dichtung
7 gasket 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
joint
Stiftschraube
10 bolt 2000002 6 2000002 6 2000004 6 2000004 6 2000004 6 2000007 6
vis
Deckel
11 cover Z26002 2 Z26002 2 Z25721 2 Z25721 2 Z25721 2 Z31610 2
couvercle
O-Ring (Viton) 3030742 3030742 3035046 3035046 3035046 3030367
12 O-Ring 2 2 2 2 2 2
O-Ring (Perbunan) 3040102 3040102 3042329 3042329 3042329 3040107
Mutter
13 nut 2100005 6 2100005 6 2100006 6 2100006 6 2100006 6 2100007 8
ecrou
Kugelhahn
16 ball valve G 1/4 1 G 1/4 1 G 1/4 1 G 1/4 1 G 3/8 1 G 3/8 1
vannes à boisseau
spherique
Küken
18 cock Z25998 1 Z25998 1 Z25889 1 Z25735 1 Z31309 1 Z31612 1
vanne à boisseau
O-Ring (Viton) 3030172 3030172 3030466 3031849 3030175 3030075
19 O-Ring 2 2 2 2 2 2
O-Ring (Perbunan) 3040158 3040158 3040501 3040117 3040119 3040121
O-Ring (Viton) 3030174 3030177
19.1 O-Ring ------- ------- ------- ------- 1 1
O-Ring (Perbunan) 3040180 3031277
Sicherungsring
20 circlip ring 2201921 1 2201921 1 2209026 1 2205389 1 2205119 1 2205119 1
circlip exterieune
Hahnschlüssel
21 plug key WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1
clef du robinet
Siebeinsatz Fabr.Nr. Fabr.No. Fabr.No. Fabr.Nr. Fabr.No. Fabr.No.
22 siebe element Filtertyp Filtertype Type de Filtertyp Filtertype Type de
élément filtrant Filtre Filtre
Dichtung
36 gasket 3380136 2 3380136 2 3382898 2 3380037 2 3380040 2 3380041 2
joint
Schraube
37 bolt 2000002 8 2000002 8 2005659 8 2005659 8 2000511 8 2000511 8
vis
Mutter
38 nut 2100005 8 2100005 8 2100006 8 2100006 8 2100007 8 2100007 8
ecrou
DDA Typ Type Type Typ Type Type
65 DPI Druck Pressure Pression Druck Pressure Pression
IPD
Zylinderschraube
70 screw 2000122 2 2000122 2 2000122 2 2000122 2 2000122 2 2000122 2
vis
Mutter
72 nut 2100003 2 2100003 2 2100003 2 2100003 2 2100003 2 2100003 2
ecrou
Federring
73 spring washer 2209799 2 2209799 2 2209799 2 2209799 2 2209799 2 2209799 2
annneau ressant
Installation and Operating Instructions for the Duplex Filter
Type 2.04.5
General:
The switchable duplex filter type 2.04.5 comprises two

filter housings which are connected in parallel through
a two-stage change-over housing. The filter housings
are designed to meet current regulations in respect of
pressure rating. The filter elements are adequately
protected to cope with the differential pressures which
occur in the filter, details of which are given on the
filter mounted instruction plates. These pressures are
1,2 bar for star-form elements and 0,8 bar for basket-
type elements.
Duplex filters are installed in cases where

regeneration of contaminated filter elements must be
carried out without shutting down the equipment or
plant.The change-over housing, which contains a
segment-type rotating valve, allows shock pressure-
free change over, because as one chamber is closed
theother chamber is opened the same amount, in otherwords, both filter chambers can be put into
operation at the same time whenever the need arises (see Picture 2 - Valve Position Indicator).
The undesired closing of both chambers is prevented by a stop, i.e.by the constructional design of
the change-over housing.
Installation:
The filter housings must not be over-stressed when tightening the filter assembly onto its base or
mounting. This also applies to the pipe connections. It is also important to make sure that the
direction of liquid flow through the filter is compatible with the filter elements installed in the filter.
The flow direction is marked on the filter assembly, usually on the flanges.
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).
I. Segment Valve Operation
The segment valve (18) is operated by the lever (21). The lever moves through an
angle of 144ø. The travel stops of the lever are located inside the change-over
housing.
A cam, which is cast integral with the neck of the segment valve extension, moves over
the valve position indicator plate (25) to indicate to the operator the position of the
segment valve (see Picture 2).
1. Changing over filter chambers:

1.1 Slacken the air vent plug (4) of the cleaned filter chamber.
1.2 Turn the lever (21) to move the position indicator cam from position "1" to position "2"
(see Picture 2). In this position the segment valve opens a port to allow liquid to flow in
and fill the cleaned chamber. As soon as the liquid flows free of air bubbles from the vent
plugt (4), close the vent plug.
2. Preparing the Filter for Operation

2.1 Position the lever (21) in the middle position - both filter chambers in operation.
2.2 Open both filter chamber vent plugs.
2.3 Start and slowly run the plant or equipment.
2.4 As soon as liquid flows from the vent plugs free of air bubbles, close the vent plugs.
2.5 Operate the lever to close one of the filter chambers; whilst the other filter chamber
takes over filtration of the liquid, the other (closed) filter chamber remains in reserve
until, due to contamination, the maximum preset differential pressure is reached. At a
differential pressure of 1,2 bar allowed for starform elements or 0,8 bar allowed for
basket-type elements, the reserve or cleaned filter chamber is to be put into operation
as follows:
2.6 Momentarily open the vent plug (4) of the reserve chamber and check to make sure that
this chamber is full.
2.7 Change over the filters as described under paragraph 1.
2.8 Open the vent plug (4) of the closed filter chamber to relieve any pressure in this
chamber. It will now be possible to check whether the segment valve (18) has in fact
closed the inlet port to this chamber.
Note that a complete sealing of a segment type valve is not possible. By opening the
sludge discharge plug (2), any liquid that has leaked passed the segment valve during
cleaning can be drained off.
2.9 Remove the filter cover (11) from the closed (shutoff) filter chamber.
2.10 Open the sludge discharge plug (2) and drain down the liquid until the liquid level is
below the seat of the element. Remove the filter element from the filter housing.
2.11 Clean the filter element (see the Operating Instructions for cleaning the element).
2.12 Replace the cleaned element into the filter housing. Make sure the seal of the element
is not damaged before replacing the element!
2.13 Replace the filter cover (11). The vent plug is
to be left open at this stage. Make sure that the
cover seal (12) and its seat are clean and in a
good condition, if necessary, renew the seal (12).
It is recommended to wet the recess for

the O-ring (12) in the Filter housing with
Vaseline to make it more difficult for the
O-ring to move..
2.14 Move the lever (21) from position "1" to position "2" - the cleaned filter chamber
will now be refilled and vented of air.
2.15 Close the vent plug - the filter chamber is now in an operational-ready condition.
3. Maintenance
Maintenance of the duplex filter extends to an inspection and eventual replacement of
the sealing elements and screens. If the filter assembly shows signs of corrosion, then it
should be reconditioned or renewed as necessary.
The filtering of cooling water and other certain types of operating mediums can lead to
formation of harmful deposits on the surfaces of the components in the change-over
housing, it is therefore advisable to operate the change-over mechanism at regular inter
vals to avoid seizure of the segment valve.
Removing and Replacing the Segment valve (18)

3.1 Open both filter chamber vent plugs (4) to depressurize the filter chambers.
3.2 Drain both filter chambers.
3.3 Using circlip pliers (DIN 5256C - Securing Borings), remove the circlip (20) from the
groove.
3.4 By rotating and at the same time lifting the segment valve (18), remove the valve
from the change-over housing.
3.5 Detach the O-rings (19).
3.6 Thoroughly clean the segment valve and examine the valve for damage. Remove any
traces of scoring by polishing the valve with a suitable, fine carborumdum paste.
Examine the valve bore in the change-over housing and if necessary treat in the
same manner.
3.7 Lightly oil the O-rings (19) and then refit them in the grooves of the segment valve. It is
recommended to renew these O-rings as, due to hardening and compression they
loose a certain amount of elasticity.
3.8 Carefully insert the segment valve (18) into the top of the change-over housing and, by
pressing down and rotating the valve at the same time, push the valve into the housing.
3.9 Position the indicator cam to point to the centre position on the valve position indica tor
plate (see Picture 2).
3.10 Now push the segment valve further down into the bore until the groove for the circlip
(20) becomes visible.
3.11 Refit the circlip (29) in the groove.
3.12 Check the segment valve for ease of operation.
3.13 Prepare the filter assembly for operation as described in paragraph 2.
1. Maintenance and Cleaning
1.1 Take the filter out of operation. See the
operating instructions for simplex and
duplex filters.
1.2 The filter chamber taken out of operation is

drained, using the discharge screw, until the
level of the liquid is below the element
support. The basket element is then
removed from the housing. The coarsest
dirt particles can now be shaken off. The
element should then be placed in a suitable
cleaning agent, e.g. BOLL CLEAN 2000,
and compressed air should carefully be
blown through the element from the outside
to the inside. For obstinate dirt, use of a soft
brush which will not damage the mesh is
recommended.
If media containing ferritec particles are to

be filtered out, the basket element is fitted
with a bar magnet (225).
1.3 Structure of the Basket Element

The basket element is a compound
structure, consisting of a bottom plate (11),
top ring (1), handle (124), support mantle
(80) and tie rod (222).
All the elements are held together on the tie rod (222). The thread on the tie rod
(222) is glued to the handle (124) so that the element can only be dismantled by
undoing the hexagonal nut (221).
The wire gauze (100) is welded from inside on to the support mantle (8).
The flow is always from the inside to the outside.
1.4 Basket element

The element is to be inspected and cleaned at regular intervals. The length of the
intervals depends on the amount of contamination expected. It is recommended,
however, that the initial cleaning should take place immediately after a new
system is flushed trough.
In general, however, the pressure drop across the filter is a good indicator of the
contamination on the filter element. This pressure drop should not exceed 0,8 bar,
since otherwise there is a danger of the element fracturing.
(Dedicated differential-pressure monitors are available from the our
product range.)
COVER SECURING DEVICE FOR DOUBLE FILTERS
The function of the cover securing

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

the venting screw (4). With the correct
switching position, the service pressure
of the filter chamber falls immediately
and hardly any fuel excapes. Otherwise,
the venting screw is immediately closed
and the fuel discharge is limited.
Operation:
1. Establish on the circuit diagram (5)

with chamber is switched off.
2. Unscrew the venting screw of this

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

cover (1).
4. Assemble in reverse order
Check seals items 6 and 7

for damage.
5. For sieve cleaning and

commissioning, see Sieve Cleaning
Operating Instructions and Double
Filter Operating Instructions.
Z45552
TYP4.36.1
01.01.00
G1/4
- +
G1/4
MATERIAL : GD - ALUMINIUM
RATING : MAX. PRESSURE 100 BAR
MAX. TEMPERATURE 150°C
RANGES OF PRESSURE DIFFERENTIAL DELTA P = 0 - 0.5 BAR

0 - 0.8 BAR
0 - 1.2 BAR TO BE SPECIDIED WHEN ORDERING
0 - 2.0 BAR
0 - 3.0 BAR
DESCRIPTION:
THE PURPOSE OF THE DEVICE IS TO MEASURE AND GIVE A VISUAL INDICATION OF A VARIABLE
PRESSURE DIFFERENCE.
METHOD OF OPERATION:
A PISTON WITH DIAPHRAGM SEAL DIVIDES THE SPACE UNDER PRESSURE INTO TWO CHAMBERS.
THROUGH THE ACTION OF A SPRING UNDER TENSION THE PISTON IS KEPT IN THE ZERO POSITION WHEN
DELTA P = 0.
AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PISTON MOVES AGAINST THE SPRING. AT
THE SAME TIME AN INDICATOR DISC IS ROTATED BY MAGNETIC MEANS, THAT IS VIRTUALLY WITHOUT
FRICTION. AS A RESULT OF THE MOVEMENT OF THE PISTON, THE RED SEGMENT OF THE DISC BECOMES
VISIBLE IN THE REGION EXTENDING FROM APROX 50% TO 100% OF THE DIFFERENTIAL PRESSURE
RANGE.
DIFFERENTIAL PRESSURE INDICATOR TYPE 4.36.1

Z21513
TYP4.36.1+4.46.1
18.01.93
GEKLEBT B
CEMENTED
COLLE
A GEKLEBT
CEMENTED
COLLE
11
A-B
10
BEI BESTELLUNG ANGEBEN

TO BE MENTIONED IN CASE OF ORDER
A MENTIONNER LORS DE LA COMMANDE
AUFTR.NR.:
ORDER NO. TYP 4.36.1
NO DE COMMANDE
11 ROLLMEMBRAN DIAPHRAGM DIAPHRAGME

10 FEDER SPRING RESSORT
7 KOLBEN PISTON PISTON
POS.NR. BEZEICHNUNG DESIGNATION DESIGNATION
SPARE PARTS ERSATZTEILZEICHNUNG PLAN DES PIECES

DRAWING DE RECHANGE
ZUM TYP 4.36.1 UND 4.46.1
DESCRIPTION AND OPERATING INSTRUCTIONS FOR THE
BACK-FLUSHING FILTER TYPE 6.62
Commission No.
CONTENTS
1. Type sheet
2. General Information on the Automatic Filter
3. Filter Installation
4. Commissioning
5. Filtration Phase Z40130 Sheet 1
6. Back-Flushing Position Z40130 Sheet 2
10. Servicing
11. Servicing Tools
12. Cleaning Agents for the Candle Elements
13. Manual Cleaning of the Candle Elements
14. Spare Part Drawing for Type 6.62
15. Spare Part List for Type 6.62
16. Type Sheet for the Differential Pressure Indicator with Electrical Contact
15. Spare Part Drawing for the Differential Pressure Indicator
2. General
The fully automatic back-flushing filter is used to filter a wide variety of fluids,
preferably fuels and lubricating oils. The candle elements are cleaned
automatically by compressed-air-assisted back-flushing without causing
interruptions to the filtration process. One clean candle element is always held in
reserve.
This self-cleaning filter basically consists of the following parts:

- the housing with the inlet and outlet flanges
- the lower housing with integrated heating chamber (circulation heating)
- the filter element assembly with the individual chambers to accommodate the
filter candles
- the pneumatic swivel drive with attached solenoid valve
- the sludge discharge valve with internal valve tappet and air receiver
- the air supply with shut-off valve, non-return valve and pressure regulator
- the flushing valve (solenoid valve) with manual initiation
- the differential pressure indicator with electrical contact
- the electric control system in its own switch box separate from the filter.
3. Filter Installation
Care must be taken during installation of the filter to ensure that the pipes attached
to the filter inlet and outlet are clean and not under tension.
The pipe selected for the sludge discharge is to be no smaller than the size
indicated in the type sheet. In order to prevent back-pressure arising in the pipe, it
is to be laid on a gradient and vented.
The terminal board on the filter is to be connected to the terminal board in the
switch cabinet by means of the control system cable (see terminal diagram).
Note: When the filter is used in aqueous media, it is imperative to observe the following:
3.1 It must be ensured that the filter does not run dry even after the supply pump
has been switched off (owing to hardening of dirt).
3.2 If this condition cannot be fulfilled, at least the electric control must be set so
that, even when the supply pump is switched off, back-flushing is initiated
every 4 hours by a time relay.
Flushing operations into a completely empty chamber for test

purposes are permitted without any restrictions. Flushing into a
partially filled chamber results in increased loading of the filter
candles. Back-flushing for installation (pipe) or control reasons into a
filter chamber which is only partially filled is therefore inadmissible!
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
The following requirements must be met for the commissioning of the filter:
4.1 Clean and dry compressed air for the control system at 4 to 10 bar operating
pressure must be available at the open shut-off valve.
4.2 Switch on the electric control using the "Main Switch" on the switch box. The
"Power" lamp and LED operating display light up.
(Activation of the main switch initiates a back-flushing cycle).
4.3 To check the electric control system, a back-flushing cycle should now be
performed by activating the "Manual" trip on the switch box.
4.4 Open the slide valve at the filter outlet. Slowly open the slide valve at the filter
inlet (avoiding pipe hammer). Then perform a further back-flushing cycle
using the "Manual" trip on the switch box. Once the back-flushing operation is
completed, the "Flushing" and the display "SP.1" lamps go off. If these
conditions are met, the filter is in the start position and is therefore ready for
operation.
After completion of a back-flushing cycle, the next back-

flushing operation can only be initiated after a time delay
(manually or by means of the differential pressure indicator).
This time delay corresponds to the time preset on the time
relay or the preselected time "PA.5" in the electronic control.
It is needed to guarantee that the cleaned filter chamber is
filled!
Note: Possible time interval calculation for time-dependent back-flushing

Let the filter run for 24 hours using the differential pressure and establish the
number of back-flushing operations (flushing cycle counter or display).
Calculate the average flushing interval.
Set the flushing interval (shortened by 30%) on the time relay or PA.2.
5. Filtration Phase (see drawing Z40130 Sheet 1)
The medium to be filtered flows through the top inlet flange into the housing (2)
and from there through the individual filter chambers to the candle elements (6).
The medium flows through the candle elements (6) from the outside to the inside
and the contamination in the medium is retained on the filter mesh of the candle
elements (6). The cleaned fluid passes to the bottom filter outlet.
In this position the air supply (by means of the solenoid valve [122]) keeps the
sludge discharge valve (valve tappet [29]) closed and compressed air is
maintained in the air receiver ready for the next back-flushing cycle.
6. Back-Flushing Position (see drawing Z40130 Sheet 2)
The contamination retained on the candle elements produces an increasing

pressure differential between the filter inlet and outlet. This difference in pressure
is indicated optically on the differential pressure indicator when a set value is
reached and an electrical contact initiates a back-flushing operation by means of
the electric control.
When the back-flushing cycle is initiated, the pneumatic swivel drive is switched
over by means of the attached solenoid valve. Several activations of the
pneumatic swivel drive (119) cause, by means of a free-wheel, the filter element
assembly (5) to turn from the clean candle element (6) held in reserve to the
candle element to be cleaned.
The activation of the clean candle element results in an immediate reduction in the
differential pressure. When the candle element (6) to be cleaned reaches the
back-flushing position, the rotary motion is interrupted by the electric control.
The solenoid valve (122) is now switched over electrically; the upper side of the
valve tappet (29) is vented. The valve tappet (29) opens the sludge discharge and
the shut-off candle element is pressure-relieved.
While the valve tappet (29) is opening, the compressed air passes from the air
receiver (26) (only after the pressure has been relieved in the candle element),
accelerates the clean fluid in the candle element (6) and presses it in
countercurrent through the candle element (6). The pressure drop thus generated
flushes the contamination deposited on the candle element (6) out of the filter
housing through the open sludge discharge valve.
After a brief blow-out period (flushing time) the solenoid valve (122) is electrically
activated, closing the valve tappet (29). At the same time the supply of stored
back-flushing air is stopped. The previously back-flushed candle element (6) is
now filled by means of the refill bore until the operating pressure has been
reached. Only then is the delay of the electric control cancelled for the next back-
flushing operation.
10. Servicing
Even automatic filters require inspection and servicing at regular intervals.

It is to be noted in particular that despite regular back-flushing the filter mesh can
become clogged over the course of time, depending on the quality of the medium
and the by-pass cleaning available. Contamination on the mesh can be removed
by cleaning the candle elements manually using an appropriate solvent (see
Section 13). An increase in the clogging on the mesh can be inferred from
progressively shorter intervals between back-flushing cycles.
The number of back-flushing cycles can be seen on the "Flushing Cycle Counter"
or on the display on the switch box.
To maintain trouble-free operation, the following points are to be noted:
a) All connections are to be regularly checked for leaks.
b) Candle elements are to be dismantled and inspected initially after 500

flushing cycles, then after 5,000 and later every 10,000 flushing cycles. If,
however, a sharp reduction in the intervals between back-flushing cycles
should occur, inspection and cleaning should be carried out sooner.
If the intervals between the back-flushing cycles suddenly become longer, all
the candle elements must be inspected for damage without fail.
c) Check the sludge discharge for leaks every 10,000 flushing cycles! No
medium should run from the end of the sludge discharge line during the
filtration phase (except during the flushing cycle).
Before the filter element assembly (5) with the candle elements (6) is
dismantled, the automatic filter must be drained by automatic back-
flushing. "Manual" activation on the switch box.
Note: The candles are subjected to wear through reciprocal loading. It is therefore
recommended that a complete set of candle elements be kept in stock.
It is expedient to renew all seals when overhauling the filter.

11. Servicing Tools
The following special tools are supplied for servicing the filter:
11.1 Special key for unscrewing the candle elements from the candle holder.
11.2 Key for opening the switch box and hand crank for operation during a
power failure.
12. Candle Element Cleaning Agent "BOLL CLEAN 2000"
The choice of cleaning medium depends on the type of the contamination. With
fuels precipitation of paraffin and asphalt or with lubricating oils mixing of different
types of oil can form solid encrustations on the mesh. Effective cleaning of fine
meshes is achieved by soaking in "BOLL CLEAN 2000" followed by blasting with
compressed air using a cleaning gun.
PRODUCT DESCRIPTION:
BOLL CLEAN 2000 is a fluid cleaning and degreasing agent with a wide range of
application. It can be used for practically all cleaning and degreasing purposes.
BOLL CLEAN 2000 cleans rapidly, thoroughly and extremely economically.
Use of BOLL CLEAN 2000 renders safety precautions superfluous.
BOLL CLEAN 2000 has these outstanding characteristics without exhibiting the
disadvantages of solvent cleaners.
BOLL CLEAN 2000 is non-flammable

does not require special marking
does not have an irritating odour
is not caustic
is physiologically unobjectionable
is biologically degradable
is registered with the Federal Office
for the Environment, Reg.-No. 04860019
BOLL CLEAN 2000 can be undercooled or overheated during storage but remains
fully usable when returned to normal temperature.
MESH CONTAMINATED WITH HEAVY OIL:

Elements contaminated with heavy oil must be soaked in a standard commercial
solvent. After soaking the elements are cleaned in the BOLL & KIRCH Type 5.04
Cleaning Device using BOLL CLEAN 2000 and high pressure pump.
INSTRUCTIONS FOR USE:

Use of BOLL CLEAN 2000 is not restricted to a particular method of cleaning.
Depending on the operating conditions, BOLL CLEAN 2000 can be used in a dip
bath, in a spraying plant, in steam jetting or in manual application using a cloth,
brush or sponge. It can be used warm or cold. BOLL CLEAN 2000 is miscible with
water - even seawater.Concentration for mesh cleaning: 1 : 2,5
Temperature: up to a maximum of 60 °C
The concentration depends on the type and thickness of the adhesive substance to
be removed. When used in concentration below 1:30 rinsing is usually not required.
No visible film remains on the surface.
13. Manual Cleaning of the Candle Elements
Observe drawing Z40357
Before the filter element assembly (5) with the candle

elements (6) is dismantled, the automatic filter must be
drained by automatic back-flushing. "Manual" activation on
the switch box.
The filter elements are to be dismantled as described below:
13.1 Remove the cheese head screws (76). Then pull the entire upper
assembly - cover (3), limit switch (128), drive attachment (4) with
pneumatic swivel drive (119) including solenoid valve (121) - up and out of
the housing (2).
13.2 Now pull the filter element assembly (5) with the candle elements (6) up
and out of the housing (2).
13.3 Then soak the filter element assembly, with the candle element openings
facing down, in a suitable tank filled with solvent. Detached contaminants
can then sink downwards out of the candle.
13.4 The soaking time and relevant solvents are:
a) In the cold cleaner BOLL CLEAN 2000, the maximum soaking time is
24 hours.
b) In Filterclean (Vecom), the maximum soaking time is 12 hours.
c) In Reiniger B85 (Vecom), the maximum soaking time is 12 hours.
d) In gas oil, the maximum soaking time is 48 hours.
13.5 After soaking, remove the entire filter element assembly from the tank and
place it on a suitable stand (e.g. perforated sheet metal) with the candle
element openings facing down and allow the solvent to drain.
13.6 Now, with the cleaning gun supplied, blow compressed air through the
candles from the inside to the outside.
13.7 After this procedure the entire filter element assembly must be immersed
again in fresh cleaner, with the candle element openings facing down, and
rinsed through with an up and down motion.
This washing procedure described in Section 13.5 may only be

carried out in a separate tank using clean solvent. The solvent
can then be used again for the next soaking operation.
13.8 Allow the filter element assembly to drain again and dry it by blowing
compressed air through it from the inside to the outside.
The manual cleaning procedure described here has produced adequate
results (approx. 60% clean) in similar applications.
13.9 Almost 100% manual cleaning is only possible, in our experience, using
the type 5.04 high-pressure cleaning unit with BOLL CLEAN 2000.
See the separate description "Filter Cleaning Unit Type 5.04".
DOCUMENTATION PARTS LIST Date 17.12.04
Page 1
Document Description
0638576 automatic filter
6.62 Gr.04 DN40
Material EN-JS1030
EN-GJS-400-15
EN 1563
Assembly Z100840
Dimension drawing Z100826
Filter room:
max. allowable pressure : 16 bar
max. allowable temperature : 160°C
Heating room:
max. allowable pressure: 14 bar
max. allowable temperature : 200°C
Test pressure : 2 x Calculation pressure
------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00001 6139924 housing lower part 1 pcs.
00002 6139920 housing 1 pcs.
00003 6130313 cover 1 pcs.
00004 5700318 distance piece 1 pcs.
00005 6130333 sieve body 1 pcs.
00006 9905005 star-pleated element according to orde 3 pcs.
00007 5906594 cover 1 pcs.
00007 5218298 nozzle 1 pcs.
00007 6712641 bow 1 pcs.
00007 2000266 slotted cheese head screw 2 pcs.
00008 2610023 float 1 pcs.
00008 2611123 pin 1 pcs.
00008 3530032 threaded pipe fitting 1 pcs.
00009 2708947 deep groove ball bearing 1 pcs.
00010 5000292 bushing 1 pcs.
00011 5130338 cover disc 1 pcs.
00011 2300374 bow 1 pcs.
00011 2300601 quick fixing device 1 pcs.
00015 6100317 carrier 1 pcs.
00016 5100341 control disc 1 pcs.
00017 2706240 freewheel 1 pcs.
00018 2206988 supporting disc 1 pcs.
00019 5004718 drive shaft 1 pcs.
00020 2206959 locking ring 1 pcs.
00021 2201003 locking ring 1 pcs.
00026 6130344 air reservoir 1 pcs.
00027 6139926 housing mud drain 1 pcs.
00028 5001563 valve face 1 pcs.
00029 5000353 valve ram 1 pcs.
00030 5100355 piston screw 1 pcs.
00031 5100356 damper bushing 1 pcs.
00035 5702156 square counter flange 1 pcs.
00036 2800063 square counter flange 2 pcs.
00037 5004049 flange heating 1 pcs.
00043 2401000 feather key 1 pcs.
................................................................................
Page 2
6.62 Gr.04 DN40
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
00044 2300016 Spring Type Straight Pin 1 pcs.
00050 3030180 o-ring 1 pcs.
00051 3030729 o-ring 1 pcs.
00052 3030180 o-ring 1 pcs.
00053 3090218 o-ring 2 pcs.
00054 3048235 o-ring 1 pcs.
00055 3098361 o-ring 1 pcs.
00056 3030063 o-ring 1 pcs.
00057 3040158 o-ring 1 pcs.
00059 3031077 o-ring 1 pcs.
00060 3098361 o-ring 1 pcs.
00061 3094563 o-ring 3 pcs.
00062 3031047 o-ring 1 pcs.
00063 3038188 o-ring 1 pcs.
00064 2785451 seal piston 1 pcs.
00065 3132369 o-ring 1 pcs.
00066 3384063 flat gasket heating 1 pcs.
00067 3380001 high pressure gasket 2 pcs.
00068 3270008 gasket 1 pcs.
00069 3270004 gasket 1 pcs.
00074 2100011 hexagon nut 6 pcs.
00075 2000482 stud bolt 6 pcs.
00076 2000155 hexagon socket head cap screw 6 pcs.
00086 2000035 hexagon screw 8 pcs.
00088 2000001 stud bolt 6 pcs.
00097 2000004 stud bolt 2 pcs.
00098 2209799 spring ring 4 pcs.
00101 2200007 disc 1 pcs.
00102 2209021 disc 1 pcs.
00104 2000205 screwed sealing plug 2 pcs.
................................................................................
Page 3
6.62 Gr.04 DN40
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
00107 2500024 screwing 4 pcs.
00108 2500025 screwing 6 pcs.
00109 2505496 screwing 1 pcs.
00110 2564886 removeable double nibble 2 pcs.
00112 2560356 angle ball valve 1 pcs.
00113 2560063 angle ball valve 2 pcs.
00115 0600642 tubing set 1 pcs.
00116 2500025 screwing 1 pcs.
00119 4503501 double piston slewing gear 1 pcs.
00120 9902572 differential pressure indicator acc. t 1 pcs.
00121 4105912 connector plug 1 pcs.
00121 2656655 solenoid valve 1 pcs.
00121 4206553 coil 1 pcs.
00122 2656655 solenoid valve 1 pcs.
00122 4206553 coil 1 pcs.
00122 4105912 connector plug 1 pcs.
00123 2650017 high pressure control device 1 pcs.
00124 2608775 non return valve 1 pcs.
00125 2614171 sound absorber 2 pcs.
00126 2600044 pressure gauge 1 pcs.
00127 2660005 safety valve 1 pcs.
00128 4200062 limit switch 1 pcs.
00129 4160351 angle cable screwing 1 pcs.
00129 4160349 reducing ring 1 pcs.
00130 5950197 connection box 1 pcs.
00131 8450198 cover for connection box 1 pcs.
00132 3380199 flat gasket 1 pcs.
00134 4105616 clamp 10 pcs.
00134 4105617 clamp 4 pcs.
00134 4100015 distance plate 3 pcs.
00137 4105801 mounting rail 1 pcs.
00138 4100085 cable gland 6 pcs.
00138 4100086 cable gland 1 pcs.
00140 9401690 type plate 1 pcs.
00141 9407569 label: "in / out" 1 pcs.
00141 9400997 label: "on / off" 1 pcs.
00141 9407396 label: "mud drain" 1 pcs.
00141 9402898 label 1 pcs.
00141 9403614 label: "compressed air connection" 1 pcs.
00145 6705032 key for unscrewing the filter element 1 pcs.
00150 4300000 control box according to order 1 pcs.
00160 5065912 flushing bush 1 pcs.
00162 5003207 thrust piece 1 pcs.
00165 2708946 deep groove ball bearing 1 pcs.
00167 3030060 o-ring 1 pcs.
00168 2310110 shaft spring 1 pcs.
Überarbeitet am : 08.12.04
Überarbeitet von : Bogda
3. Flow meter
Type: VZO 25 FL 130/25
Pos.: 3.1

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Unterhalt VD 4-413 DFE 11.00
Maintenance
Maintenance
CONTOIL â VZE / VZO 15...50
KuWo GmbH
Werkstraße 226
D-19061 Schwerin
Tel.: +49 385-640-14-0, Fax: +49 385-640-14-14
VZE / VZO / VZEA / VZOA Messaufnehmer / Mesureurs / Flow sensors
2
4
8
9
10
11
12
Pos. 12: Schrauben-Anzugsdrehmomente Zähler Schrauben Drehmoment

Pos. 12: Serrage des vis Compteur Vis Serrage
Pos. 12: Screw Torque Flow meter Screws Torque
DN 15, 20 M6 6 Nm
DN 25 M8 16 Nm
DN 40 M 12 47 Nm
DN 50 M 16 100 Nm
VD 4-413 DFE 11.00 2 KuWo GmbH

VZE / VZEA VZO / VZOA
Aufbaugruppe Aufbaugruppe
Dispositifs complémentaires Dispositifs complémentaires
Modules Modules
22 22
20 20
19
18
18
17
17
13
15
16
16
14
13
Aufb-VZE
Aufb-VZO
PRM/RZE 15.11.00 / 4-413def-02.doc
KuWo GmbH 3 VD 4-413 DFE 11.00

Pos. Bezeichnung Menge Artikel-Nr.
Pos. Description Quantité No. d'article
Pos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
VZE / VZO / VZEA / VZOA Messaufnehmer / Mesureurs / Flow sensors
1 Gehäuse 1 auf Anfrage

Corps sur demande
Housing on request
Überwurfmutter für Ausführung USA 2 37470 2961 2887

Ecrou pour version USA
Cap nuts for version USA
2 Filtersieb 1 12968 19021 12969 12970 12971

Filtre d'embout
Inlet filter
3 Messkammerdeckel PN 16,25 1 12856 19008 12861 12859 12860

Couvercle de la chambre de mesure PN 40 1 12857 19389 12862 12864 12866
Cover of the measuring chamber
4,5 Dichtung FPM 1 13002 13002 12985 12985 12985

Joint 1 13003 19020 16028 12994 13004
Gasket
6 Mitnehmer max. 130 °C 1 19154 19155 19156 19157 19383

Galet d'entraînement max 180 °C 1 19095 19045 13160 13161 13162
Driver
7 Ringkolben 1 12790 19022 12881 12882 12883

Piston rotatif
Rotary piston
8 Trennwand max. 130 °C 1 13024 -- 12963 12965 12967

Paroi de séparation max. 180 °C 1 13025 13033 13026 13027 13028
Separating plate
9 Führungsrolle VZE / VZO max. 130 °C 1 19167 19025 19168 19169 19170
Galet de guidage VZE / VZO max. 180 °C 1 19163 19025 19164 19165 19166
Guide roller VZE / VZO
Führungsrolle VZEA / VZOA max. 130 °C 1 12972 19391 12973 12974 12975
Galet de guidage VZEA / VZOA max. 180 °C 1 13146 19391 13147 13148 13149
Guide roller VZEA / VZOA
10 Messkammer PN 16 1 -- 19007 -- -- --
Chambre de mesure PN 25 1 12841 19032 12851 19551 19506
Measuring chamber PN 40 1 12842 19387 12844 19550 19507
Beim Austausch einer einteiligen Messkammer (DN 15, 25, 40 oder 50) gegen eine neue, zweiteilige
werden zusätzlich Pos. 11 (Flansch) und Pos. 12 (Schrauben) benötigt. Siehe Hinweis auf Seite 7.
Lorsqu'une chambre de mesure monopièce (DN 15, 25, 40 ou 50) doit être remplacée par une neuve,
comportant 2 pièces, il faut, en plus, pos. 11 (bride de la chambre de mesure) et pos. 12 (vis). Voir remarque
page 7.
If a measuring chamber in DN 15, 25, 40 or 50, consisting of one part, has to be replaced by a new one
(consisting of two parts), pos. 11 and 12 (flange and screws) are needed additionally. See remark on
page 7.
Korrektur Führungsrolle VZE/VZO 180°C am 28.03.01

DN 15 DN 20 DN 25 DN 40 DN 50
11 Messkammmerflansch PN 16 1 12874
Bride de la chambre de mesure PN 25/40 12877
Flange of measuring chamber PN 16...40 1 -- -- 12978 19547 19508
12 Schraube M 6 x 16 PN 16 4 12958
Vis M 6 x 16 PN 25/40 6 12958
Screw M 6 x 12 PN 16 4 19035
M 6 x 16 PN 25/40 6 12958
M 8 x 25 6 13101
M 12 x 40 8 19548
M 16 x 50 10 19549
VZE / VZEA Zähler mit elektronischem Zählwerk / Compteur avec totalisateur électronique /
Meter with electronic register
Zur Bedienung des elektron. Zählwerkes sicher stellen, dass Gebrauchsanleitung des Zählers, Art. Nr. 11601,
vorhanden ist. Umbausätze VZO in VZE oder komplette Aufbaugruppen auf Seite 11.
Le totalisateur électronique doit être adapté au compteur; la marche à suivre figure dans le mode d'emploi du
compteur, document no. 11601. Veuillez vous assurer que ce document est à disposition. Kit de conversion VZO en
VZE ou dispositifs complémentaires voir page 11.
In order to operate the electronic register assure that the manual of the flow meter, PN 11601, is at hand.
Conversion kits VZO to VZE or complete modules see page 11.
VZE / VZEA
13 Kupplungsstück max. 70 °C 1 13221 13221 13222 19740 19741
Adaptateur 130 / 180 °C 1 19742 19743 19744 19745 19746
Adapting piece
17 Elektron. Zählwerk, Liter oder US-Gallonen 1 19757 19757 19757 19757 19757
Totalisateur électronique, litres ou gallons
Electronic register, Litres or US gallons
18 Abschlussring RW 1 12903 12903 12903 12903 12903

Bague de fermeture RW
Head ring RW
20 Schrauben M 6 x 16 max. 70 °C 4 12958 12958 12958 12958 12958

Vis M 6 x 93 130 / 180 °C 4 13167 13167 13167 13167 13167
Screws
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover

DN 15 DN 20 DN 25 DN 40 DN 50
VZE / VZEA mit Impulsgeber INA / avec émetteur d'impulsions INA / with pulser INA
13 Impulsgebermodul INA, ohne Sonde max. 70 °C 1 19747 19748 19749 19750 19751
Emetteur d'impulsions INA, sans sonde max. 180 °C 1 19752 19753 19754 19755 19756
Pulser module without detector
16 Abtastsonde INA 1 13240 13240 13240 13240 13240

Sonde de détection INA
Plug-in detector INA
In Plasticbeutel enthalten / contenus dans un sachet / Included in plastic bag:

Kontaktstift 4 5560 5560 5560 5560 5560
Broche
Contact pin
und / et / and
Steckergehäuse 1 13243 13243 13243 13243 13243
Corps de prise
Plug body
17 Elektron. Zählwerk, Liter oder US-Gallonen 1 19757 19757 19757 19757 19757
Totalisateur électronique, litres ou gallons
Electronic register, Litres or US gallons

Head ring RW
20 Schrauben M 6 x 55 max. 70 °C 4 12959 12959 12959 12959 12959

Vis M 6 x 93 max. 180 °C 4 13167 13167 13167 13167 13167
Screws
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover
VZO / VZOA Aufbaugruppen / Dispositifs comprlémentaires / Modules
VZO max. 130 °C

Zähler mit Rollenzählwerk / Compteur avec totalisateur à rouleaux / Meter with roller
register
13 Kupplungsstück 1 13221 13221 13222
Adaptateur
Adapting piece
oder / ou / or
Reguliergetriebe Liter 1 12943 12888
Mouvement à réglage progressif, litres
Adjustment gear, litres
oder / ou / or
Reguliergetriebe US-Gallonen 1 19451 19452
Mouvement à réglage progressif, gallons
Adjustment gear, US gallons

DN 15 DN 20 DN 25 DN 40 DN 50
17 Rollenzählwerk, Liter 1 19216 19219 19221 12871 12873

Totalisateur à rouleaux, litres
Roller counter, litres
oder / ou / or
Rollenzählwerk, US-Gallonen 1 19440 19441 19442 19445 19445
Totalisateur à rouleaux, gallons
Roller counter, US gallons

Head ring RW
20 Schrauben M 6 x 16 4 12958 12958 12958

Vis M 6 x 55 4 12959 12959
Screws
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover
VZO max. 130 °C

Zähler mit Impulsgeber RV /Compteur avec émetteur d'impulsions RV /Meter with pulser RV
13 Kupplungsstück 1 13221 13221 13222 -- --

Adaptateur
Adapting piece
oder / ou / or
Reguliergetriebe Liter 1 12943 12888
oder / ou / or
Reguliergetriebe US-Gallonen 1 19451 19452
17 Rollenzählwerk Liter RV 0.1 l 1 19217

Totalisateur à rouleaux, litres RV 1 l 1 19218 19220 19222 13064
Roller counter, litres RV 10 l 1 13065 13066
RV 100 l 1 13067
oder / ou / or
Rollenzählwerk, US-Gallonen RV 10ppg 1 19446 19447
Totalisateur à rouleaux, gallons RV 1ppg 1 19448
Roller counter, US gallons RV 0.1ppg 1 19458 19458
18 Abschlussring RV, ohne Schauglas 1 13070 13070 13070 13070 13070

Bague de fermeture RV, sans verre
Head ring RV, without sight glass
19 Schauglas 1 13558 13558 13558 13558 13558

Verre
Sight glass
KoWo GmbH 7 VD 4-413 DFE 11.00

DN 15 DN 20 DN 25 DN 40 DN 50
20 Schrauben M 6 x 16 4 12958 12958 12958

Vis M 6 x 55 4 12959 12959
Screws
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover
VZO / VZOA max. 180 °C

Zähler mit Rollenzählwerk / Compteur avec totalisateur à rouleaux / Meter with roller
register
13 Reguliergetriebe Liter 1 12889 12944 12942 12943 12888


Head ring RW
20 Schrauben M 6 x 55 4 12959 12959 12959 12959 12959

Vis
Screws
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover
VZO / VZOA max. 180 °C

Zähler mit Impulsgeber RV /Compteur avec émetteur d'impulsions RV /Meter with pulser RV
oder / ou / or
Reguliergetriebe US-Gallonen 1 19449 19075 19450 19451 19452
17 Rollenzählwerk Liter RV 0.1 l 1 13062

Totalisateur à rouleaux, litres RV 1 l 1 13063 19030 13064 13064
Roller counter, litres RV 10 l 1 19031 13065 13065 13066
RV 100 l 1 13067
oder / ou / or
Rollenzählwerk, US-Gallonen RV 10ppg 1 -- --
Totalisateur à rouleaux, gallons RV 1ppg 1 --
Roller counter, US gallons RV 0.1ppg 1 19458 19458

DN 15 DN 20 DN 25 DN 40 DN 50
18 Abschlussring RV, ohne Schauglas 1 13070 13070 13070 13070 13070

Bague de fermeture RV, sans verre
Head ring RV, without sight glass
19 Schauglas 1 13558 13558 13558 13558 13558

Verre
Sight glass
20 Schrauben M 6 x 55 4 12959 12959 12959 12959 12959

Vis
Screws
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover
VZO / VZOA Zähler mit Impulsgeber IN / Compteur avec émetteur d'impulsions IN /

Meter with pulser IN
oder / ou / or
Reguliergetriebe US-Gallonen 1 19449 19075 19450 19451 19452
Nur für Ausführungen / seulement pour exécutions / only for versions 180°C
14 Isolierstück (inkl. Pos 20 und 21) 1 13172 13172 13172 13172 13172
Isolateur thermique (pos 20 et 21 inclus)
Isolating piece (pos. 20 and 21 included)
15 Impulsgebermodul ohne Sonde IN 0,01 l 1 13261 13261

Emetteur d'impulsions, sans sonde IN 0,1 l 1 13261 13261
Pulser module without detector IN 1 l 1 13261
oder / ou / or
Impulsgeber IN IN 1000ppg 1 13261
Emetteur d'impulsions IN 100ppg 1 13261 13261
Pulser IN 10ppg 1 13261 13261
16 Abtastsonde IN 1 13240 13240 13240 13240 13240

Sonde de détection
Plug-in detector
In Plasticbeutel enthalten / contenus dans un sachet / Included in plastic bag:

Kontaktstift 4 5560 5560 5560 5560 5560
Broche
Contact pin
und / et / and
Steckergehäuse 1 13243 13243 13243 13243 13243
Corps de prise
Plug body

DN 15 DN 20 DN 25 DN 40 DN 50

oder / ou / or
Rollenzählwerk, US-Gallonen 1 19443 19444 19444 19445 19445
Totalisateur à rouleaux, gallons
Roller counter, US gallons

Head ring RW
20 Schrauben M 6 x 93 4 13167 13167 13167 13167 13167

Vis
Screws
Nur für Ausführungen / seulement pour exécutions / only for versions 180°C
21 Verlängerung 4 13166 13166 13166 13166 13166
Rallonge
Extension
22 Deckel 1 13423 13423 13423 13423 13423

Couvercle
Cover
Gebrauchsanleitung / Mode d'emploi / User manual VZE / VZO / VZEA / VZOA 15...50
Montage und Bedienungsanleitung VD 4-419 DEF 1 11601

Instruction de montage et mode d'emploi
Mounting and operating instructions
Umbausätze / Kit de conversion / Conversion kits VZE 15...50
VZE .... 70°C VZE .... 70°C - INA VZE .... 130 / 180°C VZE .... 130 / 180°C - INA

Wichtig ! Important ! Important !
Beim Umbau eines Ölzählers VZO Lors de la modification d’un VZO en During the modification from the
zu einem VZE muss die ganze VZE, l’ensemble du dispositif VZO into a VZE, the complete
Aufbaugruppe ersetzt werden. Die complémentaire doit être changé. ancillaries related to the VZO must
neuen Teile werden mit der Les pièces de remplacement seront be dismantled. The exchanged items
Kalibrierung zum Defaultwert und livrées avec des valeurs de will be delivered with standard
Zählerständen NULL ausgeliefert. calibration standard, et le nouveau calibration values, and the counter
compteur sera mis à zéro. will be set to zero.
Die ausführende Stelle ist für die Pour celui ou celle qui entreprend la The modification remains under the
Zähleridentifikation nach dem modification, celle-ci reste sous son responsibility of the party who makes
Umbau verantwortlich. Wir entière responsabilité. Nour that modification. We recommend to
empfehlen, das Typenschild mit den recommandons de complèter la complete the name plate with the
Zählerdaten zu ergänzen. plaque d'identification avec la meter data.
spécification du compteur.
Fotos/Conversion.tif

DN 15 DN 20 DN 25 DN 40 DN 50
Umbausatz VZE .... 70°C 19776 19777 19778 19779 --

Kit de transformation VZE .... 70 °C
Conversion kit VZE .... 70°C
Umbausatz VZE .... 70°C - INA 19785 19786 19787 19788 --

Kit de transformation VZE .... 70 °C - INA
Conversion kit VZE .... 70°C - INA
Umbausatz VZE .... 130 / 180°C 19780 19781 19782 19783 19784
Kit de transformation VZE .... 130 / 180 °C
Conversion kit VZE .... 130 / 180°C
Umbausatz VZE .... 130 / 180°C - INA 19789 19790 19791 19792 19793
Kit de transformation VZE .... 130 / 180 °C - INA
Conversion kit VZE .... 130 / 180°C - INA

Messkammer, Chambre de mesure, Measuring chamber
Messkammer einteilig Messkammer zweiteilig

Chambre de mesure (1 pièce) Chambre de mesure (2 pièces)
Measuring chamber (1 part): Measuring chamber (2 parts)
DN 40 Serie-Nr. / no. de série / serial no. £ 3'741'525
DN 50 Serie-Nr. / no. de série / serial no. £ 3'587'216
Reparaturanleitung / Instructions de réparation / Repair instructions
Abbildungen / Figures / Figures
Abbildung / figure / figure 1: Abbildung / figure / figure 2: Abbildung / figure / figure 3:

· Gehäusereinigung · Grundstellung Ringkolben · Positionierung Mitnehmer in
· Nettoyage du corps · Position de base du piston Messkammerdeckel
· Cleaning of housing rotatif · Positionnement du galet d’entraîne-
· Starting position of rotary ment dans le couvercle de la
piston chambre de mesure
· Positioning of driver in cover of
measuring chamber
Abbildung / figure / figure 4: Abbildung / figure / figure 5: Abbildung / figure / figure 6:

· Positionierung Messkammerdeckel · Dichtungen · Positionierung Gehäuse auf
auf Messkammer · Joints Messkammer
· Positionnement du couvercle sur la · Gaskets · Positionnement du corps sur la
chambre de mesure chambre de mesure
· Positioning of cover on measuring · Positioning of housing on measuring
chamber chamber

Repair instructions and fault finding
This is a measuring instrument to be handled with care.
Note on safety
· When removing from pipe, observe safety instructions in the operating manual.
· When using inflammable cleaning substances, inflammable objects and liquids are to be removed from the
working area. Room to be well ventilated.
· Prior to disassembly, the measuring instrument must be free from residues that could represent a danger to
persons or test equipment. Flush thoroughly with care.
Repair instructions for measuring sensors

Replacement of filter
When removing the filter, small splinters can be formed, and these must not be allowed to enter the measuring unit.
It is therefore recommended to separate the housing from the measuring unit.
1. Remove measuring chamber screws (Item 12).
2. Remove housing (Item 1).
3. Extract filter (Item 2) with screwdriver and replace.
4. Remove deposits from housing surface and seating using fine emery-cloth (Fig. 1).
5. Clean housing connections with a cloth.
6. Fit new filter (Item 2) in housing connection. Press the metal ring into position using a round bar.
è Do not press on the filter bottom!
7. Wash housing and remove any splinters with cloth.
8. Locate the inlet and outlet space of the housing (Item 1) opposite the openings in the cover of the measuring
chamber (Fig. 6) and place housing on measuring chamber (Item 3).
9. Insert measuring chamber screws (Item 12) and tighten. Correct torque see page 2.

Cleaning or repair of measuring unit
1. Remove measuring chamber screws (Item 12).
2. Remove housing (Item 1).
3. Remove cover of measuring chamber (Item 3).
4. Remove driver (Item 6), rotary piston (Item 7), separating plate (Item 8), and guide roller (Item 9).
5. Replace worn parts and clean all remaining parts.
è For cleaning purposes it is recommended to use non-fraying cloths and kerosene or solvents.
6. Remove deposits from housing surface and seating using fine emery-cloth (Fig. 1).
7. Replace guide roller (Item 9) on pin at bottom of measuring chamber (Item 10).
8. Insert separating plate (Item 8).
9. Insert rotary piston (Item 7) with guide pin facing downwards.
è The guide pin has a larger diameter than the driver pin and is located at the center of the rotary
piston.
10. The rotary piston (Item 7) has very little clearance but can easily be rotated.
11. Rotate the rotary piston (Item 7) to the starting position (Fig. 2).
è The driver pin of the rotary piston lies on the axis of the separating plate.
12. Place the driver (Item 6) on the pin of the cover of measuring chamber (Item 3).
è Locate the long, deep, groove of the driver opposite the groove for the separating plate (fig. 3).
13. Place cover of measuring chamber (Item 3) with driver (Item 6) on the measuring chamber and press down
firmly avoiding tilting (Fig. 4).
è The cover of the measuring chamber and the measuring chamber now form a continuous surface.
When the measuring chamber is shaked in a circle, the rotary piston can move freely.
14. Treat new gaskets (Items 4 and 5) with lubricant (silicon grease) and mount on cover of measuring chamber
(Item 3) (Fig. 5).
15. Locate the inlet and outlet space of the housing (Item 1) opposite the openings in the cover of the measuring
chamber (Fig. 6) and join.
16. Align boring mark or cast mark on the measuring chamber base (Item 10) in a right angle to the housing axle.
17. Insert measuring chamber screws (Item 12) and tighten. Correct torque see page 2.
Flow meters with rotary pistons in metal must only be tested and operated using fluids having a
lubricating effect!
Repair instructions for modules

è The individual modules are not screwed together. Be careful to ensure that these do not fall apart when
removing from meter housing.
1. Note the position of the cover opening and the pulser connection in relation to the housing axle.
2. Remove Allen screws (Item 20).
3. Remove head ring (Item 18) with cover (Item 22).
4. Remove counter with clamping ring.
5. Replace worn or damaged modules.
6. Reassemble in reverse order.
Fault finding
Fault Identification Possible cause Procedure 1)

· Meter not working · Flow rate below Qmin or above · Check flow rate
· No reading on counter Qmax of meter · If flow rate too high, reduce flow
· No or very little flow or fit larger meter
· Quantity shown is too small · If flow rate too low, increase flow
or fit smaller meter
· Dirt trap filter heavily soiled · Clean dirt trap or replace filter
· Safety filter in meter inlet clogged · Fit correct filter mesh in dirt trap
· Replace safety filter in meter
· Measuring unit jammed · Remove and clean measurement
chamber, replace damaged parts
and assemble

· Quantity shown is too large · Gas or air bubbles at · Check operating conditions and
measurement position meter positioning
· Meter positioned at highest point · Thoroughly and carefully de-
of plant aerate pipes
· Pointers of roller counter do not · This is normal at high flow rates · No action necessary
rotate regularly and has no effect on accuracy of
measurement
· High pressure drop at meter exit · Dirt trap filter heavily soiled · Clean dirt trap or replace filter
· Meter runs backwards · Meter mounted in wrong direction · Mount meter with arrow in
direction of flow
· No pulse output signal · No flow · Check flow using counter
· Pulser sensor defective · Replace sensor
· Pulser module defective · Remove sensor and check
whether pulser disk rotates under
flow
· Pulser disk does not rotate · Remove pulser module, place
roller counter on first module, and
check flow using roller counter
· If the roller counter gives a
reading, the pulser module must
be replaced
Fault Identification Primary cause Recommended measures 1)

· Separating plate broken · Pressure shock due to air in pipe · Check operating conditions and
· Meter mounted in unsuitable meter positioning
position · Thoroughly de-aerate pipes and
· Gas bubbles at measuring point then slowly refill
1) Consult operating instructions
PRM/RZE 17.10.2000 - 4-413def-01.doc Art. Nr. 11723

ersetzt 14-419A.doc vom 10.01.00

4. Tanks
Type:
mixing tank 99 litres,
compensation damping
tank 19 litres,
float switch
SR1 AX 350 L A2 GL
Pos.: 4.1, 4.2, 4.1.1

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
D-27321 Thedinghausen D-19061 Schwerin
MIXING TANK
General Explanation:
Purpose of the mixing tank is to mix the warm return-flow fuel from the engine with the cold
fuel flow as provided from the daily tank. In this way the injection pumps are protected against
quick temperature shocks by switching from HFO operation to MDO operation.
The mentioned switching should not be performed during higher engine load situation (please
see engine’s operation manual). The mixing tank is equipped with a level monitoring device
(float switch, pos. 1).
Technical data:
Nominal volume: 99 litres
Maximum operation pressure: 1.0 MPa
Test pressure: 1.5 MPa
Maximum operation temperature: 149°C
Operation note:
To secure a faultless operation it is recommended to drain water daily.
Carry out the manually aerating every two weeks as described in chapter “C./D. Start-up/
Commissioning”, section 10.1 of this documentation.
1 Float switch 7 Thermometer

2 Safety valve 8 Non-return valve
3 Drain valve (secured against incidental operation) 10 Solenoid valve
4 Ventilation and aerating valve 11 Shut-off valve
5 Pressure gauge 12 Ermeto ball non-return
6 Pressure gauge valve and test valve
D - 27321 Thedinghausen D-19061 Schwerin

Telefon 04204-91 65-0 Telefon 0385-64 014-0
D-27321 Thedinghausen D-19061 Schwerin
Compensation Damping Pressure Tank

General description:
The purpose of the compensation damping pressure tank is to avoid possible pressure
peaks and to compensate the quick changes of fuel oil consumption if the fuel oil system
is manoeuvering and / or when the automatic filter is in the back flushing period.
Technical data:
Capacity: 19 litres
Maximum working pressure: 1.6 MPa
Test pressure: 2.4 MPa
Maximum working temperature: 149 °C
Equipped with:
1. Inlet valve
2. Outlet valve
3. Aerating valve
Maintenance:
To ensure perfect operation it is recommended to let out the fuel in the intervals of about
14 days so that the air cushion can be built up again to 100 per cent.
This measure can be carried on during operation.
In order to do so take the following steps:
1.) Close the fuel inlet valve of the compensation tank.
2.) Open the outlet and the aerating valve slowly.
When no more fuel is running out close the outlet and the aerating valve. Afterwards
open fuel inlet slowly.
D - 27321 Thedinghausen D-19061 Schwerin

Telefon 04204-91 65-0 Telefon 0385-64 014-0
5. Heat exchanger
Type: MX 15 L=1000
Pos.: 5.1, 5.2

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
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INSTRUCTIONS FOR SHELL & TUBE HEATER
Instruction Manual
for VESTATM MX
Table of contents for instruction manual
1. General Description........................................................................................ 1
2. Installation Space Requirements .................................................................... 2
3. Storage............................................................................................................ 3
4. Mounting and Installation............................................................................... 2
5. Connecting the Heat Exchanger ..................................................................... 3
6. Operation ........................................................................................................ 3
7. Conservation during shut down periods ......................................................... 4
8. Maintenance and Cleaning ............................................................................. 4
9. Dismantling and reassembling of the tube section ......................................... 5
10. Spare Parts ...................................................................................................... 5
Appendix:
- Spare Parts Drawing
1. General Description
Vesta MX heat exchangers are of the shell and tube type with u-tubes.
The Vesta MX heaters range from 0,5 m² to 60 m² heating surface with design
pressures 16 or 30 BAR.
Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion in
tanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water
heaters (JCW).
The heating media used is either steam, hot water or thermal oil.
Safety valve, thermometer, and pressure gauge may be mounted on a standard

outlet tube (optional).
Regulating equipment for either oil, steam or water is optional.
All heaters have been hydrostatic pressure tested before delivery.
Vesta MX heat exchangers have been 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 tube insert 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. To avoid damage it is
recommended the heater be stored in the original packaging.
3.2. Hydrostatic testing

All heat exchangers have undergone hydrostatic pressure
testing before delivery. The testing fluid used contains a certain amount of corro-
sion protection (Castrol Rustilo Aqua 2); hence no further actions regarding stor-
age are required before installation.
3.3. Extended storage

When heat exchangers are to be kept in storage for an extended period of time
we recommend Castrol Rustilo Aqua 2 be used as protection against corrosion.
4. Mounting and Installation

The heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation, the inlet pipe and media outlet pipe must face
upwards.
If the heater is placed vertically the inlet and outlet tubes as well as the media
inlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
2/5
The steam regulator (optional) must always be placed horizontally.

The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizon-
tally.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts into the holes and tighten up.
5. Connecting the Heat Exchanger

5.1. Preparation and pipe connection of the heat exchanger
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 heat exchanger.
6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securely
tightened.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.
6.2. Initial adjustments

The safety valve must be adjusted to maximum design pressure or lower.
6.3. Initial start-up

IMPORTANT: Fluid flow through the heat exchanger must be established be-
fore the heating medium is applied.
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) – T16 types
No bolts Size Torque [Nm] Tightening schedule
MX10 8 M16 50 14725836
MX15 8 M20 83 14725836
MX20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 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.
3/5
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.
6.4. Output
The output of the heater is subject to the supply of heating media at the inlet
steam valve. The steam pressure/heating media temperature applied, is to be ac-
cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-
rect layout of the condensate system avoids negative effect of counter pressure.
7. Conservation during shut down periods

Corrosion occurrences in shut down periods are mainly caused by oxygen. The
corrosion occurs if non-distilled or alkaline water remains in the heat exchanger.
However, even when fully emptied, heaters are exposed to corrosion caused by
water residues or condensation. Hence, heaters out of service should be protected
against corrosion.
If the heater is out of service for an extended period of time – in particular during
winter seasons with frost – it must be carefully emptied. Open the air escape
valve and check for clogging.
8. Maintenance and Cleaning

8.1. Regular cleaning periods
The heater should be cleaned regularly every six months by removing the tube
insert or at any time there is a decrease in output not related to other causes.
Note: The heat exchanger must be emptied before removing the tube section.
Check if any deposits have collected on the tubes.
8.2. Cleaning of tubes

Cleaning of the tube system from the outside is carried out after removing the
tube insert using a sharp liquid jet (citric acid or water).
Cleaning of the tube system from the inside is carried out after removing the
cover by flushing the tubes with e.g. citric acid.
8.3. Heavy contamination

If the heater is heavily contaminated with carbon deposits our
recommends the heater 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.
8.4. Checking the safety valves

Once every year the safety valve must be checked for correct set point.
4/5
9. Dismantling and reassembling of the tube

section
The tube section is inserted into the heater and fastened tightly between the shell
flange and the end flange. The back end of the tube section is not fixed.
The primary connection for heating media must be dismantled before disman-
tling the tube section for inspection, cleaning, etc. The tube flange has threaded
holes for dismantling screws and for mounting eyebolts for lifting devices.
Gasket surfaces are to be cleaned and protected against damage. New gaskets are
to be fitted every time the flange connection has been dismantled.
IMPORTANT: Fluid flow through the heat exchanger must be established be-
fore the heating medium is applied.
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) – T16 types
No bolts Size Torque [Nm] Tightening schedule
MX10 8 M16 50 14725836
MX15 8 M20 83 14725836
MX20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 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.
A pressure test should be carried out to prove tight joints.
Note: Pressure testing to be carried out only with insert mounted in shell.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.
10. Spare parts

When ordering spare parts please state the serial number of the heat exchanger
(located on the nameplate).
For spare parts and further information please contact KuWo GmbH.
5/5
6. Viscosity
measuring system
Type: V92,
FKKX35V4-AKAYY-AA,
92701e-99xkuw1 (loose
delivery)
Pos.: 6.1, 6.2, 6.3 (loose delivery)

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Viscosimeter
Series V92

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1
Contents
Page
1. System configuration 3
2. System description 5
2.1 Principle of operation 5
2.2 Differential pressure transmitter 6
2.3 Valve manifold 6
2.4 Heater control cabinet (only with electrically operated heat exchangers) 7
2.5 Control valve (only with steam operated resp. thermal oil operated
heat exchangers) 7
3. Operating instructions 8
3.1 First start-up or commissioning with Diesel oil 8
3.2 Change over from Diesel oil operation to heavy fuel oil (HFO) operation 9
3.3 Change over from heavy fuel oil operation to Diesel oil operation 9
3.4 Decommissioning with Diesel oil 10
4. Maintenance 10
4.1 Maintenance plan „A“ 10
4.2 Maintenance plan „B“ 10
4.3 Maintenance plan „C“ 11
4.4 Maintenance of the differential pressure transmitter 11
4.5 Cleaning of the reduction gear 12
5. Troubleshooting 12
5.1 Viscosity signal is too low 12
5.2 Viscosity signal is too high 13
5.3 Viscosity signal remains at maximum value 13
5.4 No viscosity signal 14
6. Repair instructions 15
6.1 Cleaning of the capillary tube 15
7. Spare parts list 16

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2.4 Heater control cabinet (only with electrically operated heat

exchangers)
The heater control cabinet makes for control of heating steps of the electrical heaters. A
typical example for a system with a 6-ary heater is shown in fig. 1 on page 3.
The control cabinet contains the following components:
- sequential circuit or PLC (in the quoted example: with 6 steps) for control of
the heating rods
- fuses
- transformer
- main switch
- terminal strips
- (in the quoted example: 2 x 6) contactors for switching “on” resp. “off” the
heating steps
- auxiliary contactors for locking and for alarm
Mounted in the control cabinet door:

- lamps for: voltage supply ON
indication heating steps ON
alarm
- switches for: switching over from manual operation to automatic
operation
switch “on” resp. “off” the heating steps manually
switch “on” resp. “off” voltage supply (main switch)
lamp’s test (optionally)
Functional principle:
The impulse outlet of the viscosity controller sends to the sequential circuit (in the quoted
example: with 6 steps) for control of the heater. The circuit of the sequential circuit is
factory preset.
2.5 Control valve (only with steam operated resp. thermal oil
operated heat exchangers)
The control valve makes for control the flow rate of the heating medium. It consists of a
valve body with adjusting plug (2/2-way resp. 3/2-way) and an actuator.
Fig. 2 (see page 4) shows a steam control valve as example. The viscosity controller
directly controls the actuator of the control valve.

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3.2 Change over from Diesel oil operation to heavy fuel oil (HFO)
operation
1. The system has been started up with Diesel oil already. Supply pumps and
booster pumps are running.
2. The shut-off valves (D and E, see fig. 5) at valve manifold of the transmitter
have to be opened; the counterbalance valve (F) has to be closed.
3. Check adjusted viscosity set point at controller and set the controller in
automatic operation.
4. a) with electrically operated heat exchangers (automatic operation)
Set selective switch on heater control cabinet „Man. – 0 – Auto“ in position
„Auto“. Be sure that all heating steps are turned off. If not, switch off the
heating steps using the keypad of the viscosity controller. Switch “on” the main
switch at heater control cabinet.
b) with electrically operated heat exchangers (manual operation)
Set selective switch on heater control cabinet „Man. – 0 – Auto“ in position
„Man.“. Switch on the needed heating steps by using the toggle switches for
heating steps.
c) with steam operated resp. thermal oil operated heat exchangers
Be sure, that the heating medium control valve is completely closed. If not,
switch it off manually via viscosity controller.
5. Change over the plant from Diesel oil operation to heavy fuel oil operation.
6. The system will be filled up automatically with HFO depending on
consumption of engine. Now the viscosity controller regulates automatically
the viscosity to the adjusted set point.
3.3 Change over from heavy fuel oil operation to Diesel oil
operation
1. Switch over the plant to Diesel oil operation.

2. The inflow of Diesel oil leads to dropping of viscosity. In consequence of the
nominal value default the controller switches off all heating steps automatically
(with electrically operated heat exchangers) resp. closes the heating medium
control valve (with steam operated resp. thermal oil operated heat
exchangers).
3. When the system is completely filled with Diesel oil, you should stop
viscosimeter and set controller to manual operation in order to avoid
unnecessary abrasion.

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3.4 Decommissioning with Diesel oil

1. Change over the plant from heavy fuel oil operation to Diesel oil operation.
2. Turn off trace heating. The system will be filled up slowly with Diesel oil,
that brings about a dropping of viscosity. In consequence of the nominal
value default the controller switches off all heating steps automatically (with
electrically operated heat exchangers) resp. closes the heating medium
control valve (with steam operated resp. thermal oil operated heat
exchangers). This brings about a dropping of temperature.
3. When the system is filled with Diesel oil, viscosimeter motor shall be
turned off.
4. Open counterbalance valve (F) at valve manifold.
5. Set controller to manual operation.
6. Close steam inlet resp. thermal oil inlet before control valve (only with
steam operated resp. thermal oil operated heat exchangers).
4. Maintenance
4.1 Maintenance plan „A“
Following checks should be carried out by capable personnel:
Time slice Check
Monthly Zero adjustment of the differential

pressure transmitter
4.2 Maintenance plan „B“
Following checks/maintenance procedures should carried out every 2 years:
Denomination of the part Check/Maintenance procedure
Differential pressure transmitter Zero adjust
Complete system Commissioning for checking the full

efficiency of the system
Note:
Checks according to maintenance plan „B“ as well as fault repairs, inspections and
part exchange of the viscosity sensor and associated parts must be carried out only
by a service engineer from Kupke + Wolf GmbH. Kupke + Wolf GmbH will give neither
liability nor guarantee for damages which result from the third party.

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4.3 Maintenance plan „C“

A complete overhauling of the system is advisable every 4 - 6 years. This overhauling
shall be carried out by a service engineer from Kupke + Wolf GmbH or by other qualified
service personnel provided that required spare parts are originals from
Kupke + Wolf GmbH.
Kupke + Wolf GmbH will give no liability for maintenance work carried out by the third
party.
Checks according to maintenance plan “C” are:
- checks which be considered accordingly maintenance plan “A” and “B”
- complete inspection and cleaning of all instruments
- substitution of worn and faulty parts
- fresh factory calibration of the viscosity sensor
- reassembly of the overhauled equipment and test run accomplishment
If possible the maintenance work will be carried out on the spot. But calibration of
viscosity sensor must be effected on the calibration stand in our factory. If repair on the
spot is not possible, the corresponding part and/or other system components must be
overhauled in the factory or nearest service representative.
For service work aboard a ship the service engineer must be provided with all
necessary labour, equipment, tools, and appliances (fuel, oil, current, air pressure etc.).
Guarantee terms of Kupke + Wolf GmbH apply for maintenance work which is carried
out by our authorized service engineer.
4.4 Maintenance of the differential pressure transmitter

The differential pressure transmitter requires minimum of maintenance under normal
operating conditions.
Zero check is to be carried out monthly as follows:
Note: It is possible only to carry out this check only when the viscosimeter system is
in operation and voltage supply is switched “on”.
1. Switch over the system to manual operation.
2. Open counterbalance valve (F, see fig. 5 on page 8) at valve manifold of the
differential pressure transmitter and turn off viscosimeter motor.
3. When output signal of the differential pressure transmitter is correct (4 mA),
the controller display indicates „0.0“. If not, adjust zero at differential pressure
transmitter.
4. Turn on viscosimeter motor and close counterbalance valve (F) at valve
manifold.
5. Set viscosity controller to automatic operation.

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4.5 Cleaning of the reduction gear
The reduction gear is already filled with gear oil at manufacturer’s side. The gear
requires no maintenance under normal operating conditions apart from exchanging the
gear oil after 10,000 hours of operation resp. 2 years of operation.
Clean reduction gear as follows:
1. Dismantle reduction gear and electric motor from viscosity sensor.

2. Disassemble electric motor from gear.
3. Remove side cover of gear after dismantling the four socket head screws.
4. Clean gear with a solvent and dry with clean air pressure.
5. Assemble electric motor on gear.
6. Fill gear with 200 ml gear oil (Shell Tivela, Shell Omala 220 or similar).
7. Mount side cover and reattach gear motor at measuring flange of the
viscosimeter.
5. Troubleshooting
5.1 Viscosity signal is too low
Possible cause Corrective action
Sensing lines between viscosimeter Tighten couplings.

and transmitter (plus side) leaking. Repair leaks.
Air entrapped in sensing lines

between viscosimeter and transmitter. Vent sensing lines.
Incorrect zero adjustment. Adjust zero.

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5.2 Viscosity signal is too high

and transmitter (minus side) leaking. Repair leaks.
Incorrect zero adjustment. Adjust zero.

Clean measuring capillary
Measuring capillary clogged.
(see section 6.1 of this description).
5.3 Viscosity signal remains at maximum value
Fuel to cold before start-up. Start system in accordance with

section 3.2 or heat sensing lines.
Fuel to cold during normal system Check control connection between

operation. controller and control unit (control valve
resp. heater control cabinet).
Check control valve (if existing).
Differential pressure transmitter Contact Kupke + Wolf GmbH.

malfunctioning.

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5.4 No viscosity signal
Viscosimeter is not running. Check motor protecting switch.

If motor switch „on“, check electricity.
Motor rotates in wrong direction. Reserve 2 of the 3 leads at terminal strip

of motor.

and transmitter leaking. Repair leaks.
Air entrapped in sensing lines after Vent sensing lines.

repair.
Shut-off valves at valve manifold are Ensure that shut-off valves are open
closed or counterbalance valve is resp. counterbalance valve is closed.
open.
No electrical supply at differential Check integrity of electrical connections.

pressure transmitter. Check fuses.
Differential pressure transmitter Contact Kupke + Wolf GmbH.

malfunctioning.

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6. Repair instructions
6.1 Cleaning of the capillary tube
Denomination of parts see fig. 6 in chapter 7.
1. Turn off viscosimeter motor.

2. Open by-pass valve (L, see fig. 5 on page 8).
3. Remove gear motor (pos. 10). Dismantle screw (pos. 7).
4. Remove measuring flange. Remove screw (pos. 30).
5. Remove damping capillary (pos. 36) after removing the screws (pos. 37).
6. Soak damping capillary in cleaning-fluid and clear it by blowing through it
with air pressure.
7. Remove measuring capillary (pos. 35) by unscrewing anticlockwise via
screw-wrench.
8. Soak measuring capillary in cleaning-fluid and clean it with a soft fitting
wire.
9. Clear the measuring capillary by blowing through it with air pressure.
10. Reassemble the measuring flange last in - first out.
Take care that the capillary tube is sealed well.
11. Install measuring flange.

12. Reattach gear motor.
13. Turn on viscosimeter motor.
14. Vent the differential pressure pipes.
15. Close by-pass valve (L).

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7. Spare parts list

Pos. no. Part no.
(fig. 6) Quantity Denomination (LG-No.) Material/Size
1 1 housing VN006 Cast steel GS 52
4 1 ring VN084 OD 116 x ID 92 x 2 mm
5 1 drive console VN024
6 3 spring washer VN161 M12, spring steel
7 3 hexagon head screw VN162 M12 x 40; steel 8.8
8 1 assy magnet outside VN023
9 2 safety screw VN163 M6 x 6; steel 45 H
10 1 electric motor and gear VN034
11 1 pin V12 (long) VN010 steel
12 * 1 gear pump VN012 stainless steel
13 1 O-ring seal VN008 Viton, ID 12.00 x 1.00 mm
14 1 plate, gear pump VN043 steel
15 1 pin V12 (short) VN011 steel
17 2 screw connection VN165 1/4“ NPT x 10 mm
19 4 hexagon head bolt VN167 M6 x 70 mm
21 1 plate, gear pump VN169 steel
22 4 spacer VN170 steel
23 1 drive shaft VN025
24 2 ball bearing VN026 10 x 19 x 5 mm
26 1 ring nut VN140
27 1 snap ring VN027
28 1 assy magnet inside VN022
29 1 magnet cap VN021
30 4 socket head screw VN171 M12 x 50 mm
33 4 hexagon head screw VN174 M6 x 20 mm
35 * 1 measuring capillary 0 – 50 mPas VN157
36 1 damping capillary 25 – 50 mPas VN031
37 4 screw VN175 M4 x 16, steel
-------- 1 measuring flange VISCS1
* = No individual order possible because this is an integral part of measuring flange. Measuring flange
requires factory calibration.

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Instruction Manual
FCX-CII SERIES TRANSMITTERS
Differentiel pressure Transmitter (FKK ...4)

Pressure Transmitter (FKP...4)
Pressure Transmitter with remote seal (FKP, H...E)
Absolute Pressure Transmitter (FKH...4)
INF-TN3FCXC2b-E
CONTENTS
INTRODUCTION.......................................................................................i
CAUTION ON SAFETY.............................................................................ii
CAUTION ON USE……………………………………………………… iv
CONFIRMATION OF YOUR SPECIFICATION……………………….. iv
OUTLINE………………………………………………………….. 1
OPERATING PARTS AND THEIR FUNCTIONS………………. 2
OPERATION AND SHUTDOWN………………………………... 4

3.1. Preparation for operation…………………………………….. 4
3.2. Operation…………………………………………………….. 6
3.3. Shutdown…………………………………………………….. 7
MAINTENANCE…………………………………………………… 9
4.1. Periodique inspection………………………………………… 9
4.2. Troubleshooting……………………………………………… 10
4.3. Replacement of parts…………………………………………. 11
SPARE PARTS………………………………………………………14
INTRODUCTION
INTRODUCTION
Thank you very much for your purchase of the Fuji FCX-CII Series Transmitter.
This instruction manual covers the FCX-CII series transmitter and contains information about the
installation, piping, wiring, operation and maintenance of the FCX-CII series (FKK...4 • FKP...4 •
FKP...E).
• First read this instruction manual carefully until an adequate understanding is required, and then
proceed to installation, operation and maintenance of the FCX-CII Series transmitter.
• The specifications of the transmitter will be changed without prior notice for further product
improvement.
• Modification of the transmitter without permission is strictly prohibited. Fuji will not bear any
responsibility for a trouble caused by such a modification.
• This instruction manual should be kept by a person who is actually using the transmitter.
• After reading this manual, keep it at a place easier to access.
• This manual should be delivered to the end user without fail.
• For detail specifications and outline diagrams, refer to the specifications furnished separately.
The product conforms to the requirements of the

Electromagnetic compatibility Directive 89/336/EEC as
detailed within the technical construction file number
TN513035. The applicable standards used to demonstrate
compliance are :-
EN 50081-2 :-1993 Conducted and Radiated emissions
EN 50082-2 :-1995 Radiated immunity, ESD and FBT
Type: Described in nameplate on main frame (see Page iv)

Date of manufacture: Described in nameplate on main frame
Product nationality: France
Request
Issued in February, 2002
• Transcription of a part or the whole of this manual without per-
mission is prohibited.
• The contents of this manual are subject to change without prior
notice.
i
CAUTION ON SAFETY
First of all, read this “Caution on Safety” to ensure correct operation of the
transmitter.
• The cautionary descriptions listed here contain important information about safety, so they should be
observed without fail. Those safety precautions are classified into ranks “DANGER” and “CAUTION”.
Wrong handling may cause a dangerous situation, in which there is a
DANGER risk of death or heavy injury.
Wrong handling may invite a dangerous situation, in which there is a
possibility of medium-level trouble or slight injury or only physical
CAUTION damage is predictable.
On items listed under “ CAUTION ”, they may also lead to serious accidents depending on circum-
stances, and must be fully observed.
• The signs of prohibition and indication are explained in the following.
PROHIBITION General items which pertain to prohibition (DO NOT)
INDICATION General items which pertain to user’s action
Installation and Piping
DANGER
• Non-explosion-proof transmitter must not be used in a place with explosive gases to prevent
serious accidents such as explosion, fire, etc.
CAUTION
• The transmitter is heavy. Be careful when handling it.
• The transmitter should be installed in a place that meets the operating conditions shown in DS
sheet or this instruction manual.
• Install the transmitter according to the instruction manual. Improper installation may lead to the
cause of fall, trouble or incorrect operation.
• When installing, make sure that the transmitter interior is free from cable chips and other foreign
objects to prevent fire, trouble, or incorrect operation.
• When power is ON, do not change the position of the field indicator in an explosion-proof area.
• When power is ON, do not change the position of the transmission unit in an explosion-proof area.
• When power is ON, do not change the angle of the indicator.
• Main valve used for piping should be selected with the maximum pressure of the process taken
into account (piping parts such as main valve, etc. should be furnished by user). If the main valve
and other parts do not meet the rating, it may result in leakage of gas or liquid which could lead to
hazard.
• Pressure pipes to be used must meet the temperature/pressure rating.
ii
Wiring
DANGER
• On explosion-proof type transmitter, its wiring work must be performed according to the required
laws and regulations. Incorrect wiring may cause explosion, fire or other serious accidents.
CAUTION
• Before making wiring work, be sure to turn OFF the main power to prevent electric shocks.
• Use wiring materials of correct rating to prevent fire accidents.
• Connect a power source of correct rating to prevent fire accidents.
• The transmitter should be grounded as specified to prevent electric shocks or incorrect operation.
• After installing the transmitter, firmly close the covers of the transmission unit and terminal box.
If not, rain water enter the transmitter which may result in trouble or incorrect operation.
Adjustment of Smart Type
DANGER
• When using a flame-proof transmitter, do not connect HHC to the transmitter terminals and junc-
tion terminals.
Replacement of Maintenance Parts
DANGER
• When removing an explosion-proof transmitter, turn OFF the main power, then disconnect the
piping and wiring. Do not remove it when the power is ON to prevent serious accident such as
explosion, fire, etc.
iii
CAUTION ON USE
Be sure to observe the following Instructions
Storage for a long period

Store the transmitter in a dry room at normal temperature and humidity.
Keep protection caps in place at the conduit connection and process connection.
For installation, select an appropriate place

Site at location with minimal vibration, dust and corrosive gas
At a place allowing an adequate space for checkup

Site at location large enough to allow maintenance and checking.
Mounting angle
Mount to a pipe horizontally or vertically.
Attention to overload
Do not apply a pressure outside the specified range.
Other
Besides the above, be sure to observe the cautions given in this manual.
CONFIRMATION OF YOUR SPECIFICATION
The instrument nameplate as shown below is attached at the transmission unit of this transmitter. Before
use, make sure the contents of the nameplate agree exactly with your specifications.
Tag No.
Series
Type M.W.P.
Range
Ser.No.
Power Supply
Output 4 ... 20mADC Mfd.
Fuji Electric Co., Ltd. Made in Japan
iv
OUTLINE
The FCX-CII series transmitter detects the differential pressure or pressure of various
fluids, converts it into a current signal of 4 to 20 mA DC and transmits it.
All the adjustment functions are incorporated in the transmission unit for making
adjustments easily and exactly.
Transmitter settings (such as range and damping time constant, etc.) can be changed from
an HHC (Hand Held Communicator).
Principle
The operating principle of the FCX-CII series transmitter is shown in the block
diagram below.
The input pressure is changed into an electrostatic capacitance in the detecting unit.
The change proportional to the pressure undergoes conditioning and amplification in
the transmission unit, and is then output as a current of 4 to 20mA DC.
Displacement Capacitance
Input change
differential Diaphragm Sensor
pressure
Detecting unit
Measuring Operational Output

amplification current
circuit circuit
Transmission unit
1
OPERATING PARTS AND THEIR FUNCTIONS
FCX-CII Series transmitter
Process connection
Detecting unit
Transmission unit
Vent/drain Conduit
plug connection
Zero/span
Terminal unit adjustment
screw
Terminal unit
CK+
CK–
–
Description of FCX-CII Series transmitter

Part name Description
Detecting unit Detects pressure, differential pressure or level of fluid.
Transmission unit Converts the detected signal into an output signal.
Vent/drain plug Used for gas discharge or draining. (Attention should be paid
under a high pressure.)
Process connection Connects impulse pipes from the process.
Conduit connection Connects the output cable.
Zero adjustment screw Adjusts zero. (For analog type, refer to Section 7.)
Terminals
Symbol Description
+, - Connects the output cable.
CK+, CK- Used for checking the output or connecting an indicator.
An external terminal used for grounding
2
OPERATION AND SHUTDOWN
3.1 Preparation for operation

Before operating the transmitter, be sure to perform the following checks and procedures. Note
that adjustment is required in a non-hazardous area for zero point check of intrinsically safe
explosionproof and flameproof transmitters, do not open terminal cover and do not use HHC.
Use the transmitter indicator and the external adjustment screw.
Preparation procedure
(1) Check for liquid or gas leakagefrom the process

connection, etc. by applying soapy water or the
like.
(2) Check the signal wiring according to the “Terminal block connection diagram” shown in 4.1
(Page 16).
(3) Vent gas from the transmitter.
Important When the plant requires chemical cleaning at the start of operation, be sure to
close the valve of the transmitter to prevent entry of cleaning liquid into the
pressure receiving unit.
(4) Perform zero point adjustment.
4
Zero point check
Turn on the power to the transmitter.

Check the output signal of the transmitter by connecting a DC ammeter across CK+ and CK– of
the terminal block.
After ten minutes or longer, adjust the transmitter output current to 4 mA (zero adjustment). (See
below.)
(1) Zero adjustment

Zero point of the transmitter is adjustable by the zero screw on the electronics housing with
the zero adjustment screw.
• If the transmitter is locked (see section
Decrease
“Operating procedure”, Lock of adjustment
function), it is not possible to adjust with the
external adjustment screw. Increase
• When a digital indicator is attached to the

transmitter, make sure that the LCD lamp
“ZERO” is ON.
(2) Adjustment by HHC

Refer “zero adjustment” explained in section 7.1.
When all the checks and preparatory operations are finished, tighten the cover securely. (Tighten-
ing torque 20 N•m {2 kgf•m} <14ft-lb>)
Important 1. After adjustment of the transmitter, it should be kept energized for about 10
seconds to write the adjustment result into memory.
2. Use a blade-edge screwdriver for adjusting the zero/span adjustment screw.
5
3.2 Operation
(1) Operation of pressure(FKP) and absolute (FKH) transmitter
Open the valve slowly to apply a pressure. When a pressure is applied, the transmitter is set
in the operating status.
Open
(2) Operation of differential pressure transmitter (FKK)

Set the operating status by manipulating the manifold valve.
Stop valve
on the low
pressure side
Open Make sure the equalizing valve is open.
Stop valve
on the high
pressure side
Equalizing
valve
Open the stop valve on the high pressure side slowly.
Open
Close Close the equalizing valve.
6
Open
Finally, open the stop valve on the low pressure side
slowly.
Check of operating status
Use a field indicator, receiving instrument or HHC to check the operating status.
3.3 Shutdown
(1) Shutdown of pressure (FKP) and absolute (FKH) transmitter
Close the valve slowly to stop applying a pressure. The transmitter is set in the measurement
stop status.
Close
7
(2) Shutdown of differential pressure transmitter
Set the shutdown status by manipulating the manifold valve.
Turn off power supply.
Close the stop valve on the high pressure side (H side)

slowly.
Close
Open
Open the equalizing valve.
Close
Close the stop valve on the low pressure side (L side)

slowly.
Before a long shutdown, discharge the process fluid and drain completely from
Important
the transmitter.
This is to protect the transmitter from freezing, corrosion, etc.
8
MAINTENANCE
4.1 Periodic inspection

In order to ensure the measurement accuracy and long life of the transmitter, it is
essential to inspect the transmitter periodically according to the operating conditions.
Visual inspection
Visually inspect each part of the transmitter for damage, corrosion, etc.
If you detect any material which may cause corrosion, it should be cleaned off.
Check of cover and O-ring

The transmitter has a water and dust-proof construction.
Make sure the O-ring of the case cover is not damaged or deteriorated.
Carefully prevent foreign materials from sticking to threads.
Piping leakage check

Using soapy water or the like, check the all process connections for leakage of
process fluid. If necessary, drain the moisture which has accumulated in
the transmitter and process pipe.
9
4.2 Troubleshooting
If an abnormality occurred in the process or transmitter, action should be taken with reference to the
table below.
Symptom Cause Remedy
(1) The manifold valve does Repair the valve so that it opens/closes normally.
not open/close normally.
(2) Pressure leak is occurring. Repair a leak.
(3) Process piping is improper. Make correct piping.
(4) Process pipe is clogged. Eliminate the cause of clogging.
(5) Power supply voltage Make arrangement to obtain proper values.
and/or load resistance is (For power supply voltage and load resistance,
improper. refer to “7.2” (page 50).)
Output (For intrinsically safe installations, the power
current supply voltage should be 10.5 to 26V DC for
overshoots smart type.)
scale (6) Voltage between the Check for faulty cable, insulation, etc. and repair
(exceeds external connection as needed.
20mA). terminals of transmission (For power supply voltage and load resistance,
unit is wrong. refer to “7.2” (page 50).)
(For intrinsically safe installations, the power
supply voltage should be 10.5 to 26V DC for
smart type.)
(7) Zero and span are not Readjust according to sections 4 (page 9).
adjusted.
(8) Electronics unit is faulty. Replace the electronics unit according to 5.3 (page
32).
(1) Same as (1) to (4) above Correct wiring (according to 7.1 (page 48)).
(2) Power supply polarity is
wrong.
(3) Power supply voltage and/ Make arrangement to obtain proper values.
or load resistance is (For power supply voltage and load resistance,
No output improper. refer to “7.2” (page 50).)
current (less (For intrinsically safe installations, the power
than 3.8 mA). supply voltage should be 10.5 to 26V DC for
smart type.)
(4) Voltage between the Check for faulty cable, insulation, etc. and repair
external connection as needed.
terminals is wrong. (For power supply voltage and load resistance,
refer to "7.2" (page 50).)
(For intrinsically safe installations, the power
supply voltage should be 10.5 to 26V DC for
smart type.)
32).
(1) Process piping is improper. Correct the piping.
Output current (2) Gas or solution is mixed in. Vent or drain the transmitter.
error (3) Liquid density changes. Perform density compensation.
(4) Ambient temperature Minimize the temperature change.
changes widely.
(5) Zero or span has deviated. Readjust zero or span.
32).
If remedy is impossible, contact Fuji Electric’s service department.
10
4.3 Replacement of parts
If the transmitter requires a replacement part, drain process fluid from the transmitter,
disconnect it from the process and carry out replacement in an instrument room.
When removing an explosion-proof transmitter, turn OFF the main power, then dis-
connect the piping and wiring. Do not remove it when the power is ON to prevent
DANGER serious accident such as explosion, fire, etc.
To identify faulty part
Replace the transmission unit with a spare one in order to determine whether it is the
detecting unit or transmission unit which is faulty.
When the faulty unit is identified, it should be replaced with a new one.
Replacement of electronics unit
Replacing procedure
Electronics unit
(1) Turn off the power supply.
(2) Remove the indicator.
Indicator
(3) Remove the electronics unit.
Unplug each connector.
(4) Remove the stud bolts which fastens
Connection at rear
the indicator. of electronics unit
(5) Replace the electronics unit with a

new one and assemble it by
reversing the above procedure from
(4) to (1).
Important When installing the electronics unit, make sure that the
zero adjust screw and the volume control are posi-
Volume control
tioned as shown the right. Zero/span
adjustment screw
(6) After completion of replacement, perform zero and span adjustments.
Important The electronics unit should be removed carefully so as not to damage the internal
wiring.
11
Replacement of detecting unit
Transmission unit
Detecting unit
Flexible printed circuit board
Hexagonal socket bolt
Replacing procedure
(1) Remove the electronics unit according to “Replacement of electronics unit”.
(2) Remove the hex. socket bolts from the electronic housing.
Pull the electronics housing straight forward and away from the detecting unit.
(3) Replace the detecting unit with a new one of the same type.
(4) Fit the transmission unit to the detecting unit and tighten it.
(5) Connect each connector of the electronics unit and attach it to the transmission
unit.
(6) After reassembly, carry out zero and span adjustments.
Important • Ensure that replacement detector unit is the same specification as the original
by comparing dataplates.
• When removing the transmitter case, pay attention not to damage the flexible
printed circuit board.
12
Replacement of the internal parts of detecting unit
In case of differential transmitter (code symbol : FKK/FDK) :
Nut
Seal diaphragm
O-ring
Measurement
chamber
detecting cover
Seal tape
Bolt
Seal tape
Replacing procedure
(1) Remove four hexagon socket head bolts with a torque wrench, etc..
(2) Disassembly gives access to the casing covers, O-rings, hexagon socket head bolts and nuts.
(3) After disassembly, replace the faulty part with a new one.
(4) Before reassembly, clean the O-ring face of casing cover with the soft cloth immersed in
water, alcohol, or similar detergent.
(5) Reassemble the detecting unit by reversing the disassembling procedure. The casing covers
should be assembled so as to be symmetrical with each other in the left-right direction and
carefully so as not to damage the seal diaphragm. Tightening torque should follow the table
below.
Tightening Maximum working

torque pressure
Bolt size Bolt material [N•m] [MPa] Application
(kgf•m) {bar}
<ft-lb> <psi>
50 42
M10 Cr-Mo steel (5) {420} Working pressure 42 MPa {420 bar} <6000 psi> or less
<36> <6000>
SUS304 30 10
M10 ASTMB7M (3) {100} Working pressure 10MPa {100 bar} <1400 psi> or less
ASTML7M <22> <1400>
50 42
M10 SUS630 (5) {420} Working pressure 42 MPa {420 bar} <6000 psi> or less
<36> <6000>
(6) After assembly, carry out a pressure test. Apply a pressure equal to 150% of the maximum
working pressure to both high pressure (H) and low pressure (L) measurement chambers of
the transmitter simultaneously for 15 minutes, and make sure there is no leakage.
13
SPARE PARTS
This diagram shows main parts of the differential pressure transmitter, pressure transmitter.
For details, contact our office.
C-7
C-17
B-17
C1~4
B-16
B-12
B1~5
A-1
B-8
A-3
B-9
B-16
A-5
A-5A
B-14
A-5
A-31A
A-39
A-40
A-12
A-6
A-12A
A-41
12
28
A-40
A-10
A-13A
A-20A
A-11A
A-24A
A-2
14
No. Parts No. Part Name Q’ty Material Remarks
A-1 * ZZPFCX4-A010 Cover 1 Aluminium alloy Blue

ADC12
A-2 * ZZPFCX4-A020 Cover 1 Aluminium alloy Blue
ADC12
A-3 * ZZPFCX4-A030 Cover ass'y 1 Aluminium alloy With indicator
ADC12
A-5 * ZZPFCX4-A050 Indicator 1 Analog, 0 to 100% linear
* ZZPFCX4-A051 Indicator 1 Analog, 0 to 100% square-root
* ZZPFCX4-A052 Indicator 1 Analog, dual scale
* ZZPFCX4-A053 Indicator 1 Analog, actual scale
* ZZPFCX4-A054 Indicator 1 LCD Meter
* ZZPFCX4-A054A Indicator kit 1
A-5A * ZZPFCX4-A05A Unit name plate 1 LCD Indicator type
A-6 * ZZPFCX4-A061 Amplifier unit 1
A-9 * ZZPFCX1-A091 Switch over plug 1 Normal/Reverse action switch over plug.
A-10 * ZZPFKK1-A101 Electronics housing 1 Aluminium alloy With Pg13.5 connection
ADC12
* ZZPFKK1-A102 Electronics housing 1 Aluminium alloy With NPT1/2 connection
ADC12
* ZZPFKK1-A103 Electronics housing 1 Aluminium alloy With M20 x 1.5 connection
ADC12
A-12A * ZZPFCX4-A121A Plug kit 1 Plug for Pg13.5 connection.
* ZZPFCX4-A123A Plug 1 Plug for M20 x 1.5 connection.
A-12 * ZZPFCX1-A122 Plug 1 Stainless steel Plug for NPT1/2 connection.
* ZZPFCX4-A121 Plug 1 Aluminium alloy Plug for Pg13.5 connection.
ADC12
* ZZPFCX4-A123 Plug 1 Aluminium alloy Plug for M20 x 1.5 connection.
ADC12
A-13A * ZZPFCX4-A132 Terminal block unit 1 Round washer type.
* ZZPFCX4-A133 Terminal block unit 1 Wire retaining washer type.
* ZZPFCX4-A134 Terminal block unit 1 Round washer type with arrester.
* ZZPFCX4-A135 Terminal block unit 1 Wire retaining washer type with arrester.
A-20A * ZZPFCX1-A200A Cable gland kit 1
A-24A * ZZPFKK1-A240A Fastener kit 1
A-31A * ZZPFCX1-A310A Hex. socket screw kit 2 Minimum order q’ty 10 pcs.
A-39 * ZZPFCX2-A390 Blank name plate 1 Standard (Minimum order q’ty 5 pcs.)
A-40 * ZZPFCX1-A400 Rivet 4 Minimum order q’ty 50 pcs.
15
No. Parts No. Part Name Q’ty Material Remarks
B-1~5 –––––––– Detecting unit 1 Contact our office for inquiry

(Differential pressure and Flow)
B-8 * ZZPFCX4-B080 O-ring 2 Viton 
 Minimum order q’ty 10 pcs.
* ZZPFCX4-B081 Square section gasket 2 Teflon 
4th digit of
type code
B-9 * ZZPFCX4-B091 Cover 2 SCS14 S
* ZZPFCX4-B093 Cover 2 SCS14 T,X
* ZZPFCX4-B095 Cover 2 SCS14 V,W
B-12A * ZZPFHC1-B122 Vent/drain kit 2 NPT1/4

B-14 * ZZPFHC1-B143 Bolt/Nut kit 4 C.S.
* ZZPFHC1-B144 Bolt/Nut kit 4 Stainless steel Up to 10MPa {100kgf/cm2}
* ZZPFHC1-B145 Bolt/Nut kit 4 Stainless steel Up to 14MPa {140kgf/cm2}
B-16 * ZZPFHC1-B160 O-ring 1 Chloroprene Minimum order q’ty 10 pcs.
B-17 * ZZPFHK1-B171 Mounting bracket kit 1 Stainless steel
C-1~4 –––––––– Detecting unit 1 Contact our office for inquiry
(Pressure)
C-7 * ZZPFHP1-C071 Adapter 1 Stainless steel Rc1/2
* ZZPFHP1-C072 Adapter 1 Stainless steel NPT1/4
C-17 * ZZPFHP1-C171 Mounting bracket kit 1 Stainless steel
16
Industry controller type kuwo 9... B 9... E
Installation and connection Page 2 of 8
Installation:
Before installation inspect the controller for any visible signs of damage caused during transport
Check power supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.
Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following the
wiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays.
- Phase wire and neutral wire must not be transposed.
Putting into operation:

Switch on power supply. Digital display and control lamps will light up according to
the setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panel
of the controller and the electrical wiring. Adjust set value and check other adjustments.
Maintenance:
All electronic controllers in the kuwo range are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against mechanical
damage and inadmissible operating conditions, it should give years of trouble-free service.
In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself.
(bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent
inspection and fault repair more difficult and can cause considerable damage to the circuitry.
For repair remittance remove plug board with connected leads on the rear side,
loosen fastening devices and remove controller from the panel.
In case of remittance please give precise details of the fault to reduce time and cost of repair.
Error messages:
Err 1...6 Fault on measuring input nr. ...
check measuring lines for short circuit or breakage
check measuring input by connecting a RTD
Err 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,
configuration of the parameters has to be checked
Err 50 Hardware error in program section
Err 52 Hardware error in data section
no further operation possible, remit controller for repair
Error messages during self adaptation:

Err 202 Ambient conditions are not suitable for self adaptation;
adjust parameter manually
Err 205 routine exceeded the setpoint
raise setpoint or lower actual value and start adaptation again
Err 206 Fault on measuring input during adaptation;
check the wiring and start adaptation again
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Operation Page 3 of 8
Operating status:
The upper display shows the actual value (channel / measuring input 1),
the lower display remains empty or (depending on the version and settings) shows
- the attendant unit of measure (°C, °F, %...)
- an additional actual value, the setpoint value or the controller output value Y
- or the additional actual value only when the key is pressed.
Alternative type:
switch over the upper display to the several actual values by pressing the key,,
the lower display shows the number of the attendant measuring input.
Setpoint value setting:
press - key shortly (do not hold down)
The upper display shows the abbreviation of

the activated setpoint adjustment mode,
the lower display shows the adjusted value.
The indicated value can now be changed by the (lower) and (higher) -keys..
Each variation of the set value is immediately active, without any more operating steps.
The arrow keys have a built-in accelerator mode:
longer pressing causes faster alterations.
Return to operating level:

Press - key shortly (or automatically after 30 seconds without any key-action)
optional: Press - key shortly again: *SP =set values of further control loops (*=no.) /
SP* =further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is not active at the moment.
Manual operation: (optional)
Hold down - key and press - key, then release both keys..
(optional: switch on and off using separate - key)
(for multi-channel controllers first enter the channel number*,
and press - key, then:)
The lower diplay shows „H *“ and - if activated - the output position.

The upper display still shows the actual value. The automatic control is interrupted.
Manual control is now possible using the ... - keys..
Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)
optional: starting the self adaptation (ref. to chapter Optimization):

On manual operation level - key >5 sec ;
the lower display indicates „-Ad-“.
Cancel: - key >5 sec again
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Parameter level Page 4 of 8
Access from operating level.
Unlock the access first:

Turn the switch on the rear panel of the controller to position „U“ = unlocked
(Lock access after the adjustments: Switch position to „L“ = locked).
After the parameter level (refer to the instructions to each level ) has been invoked,
the first setting is shown and can be modified.
It is not possible to invoke the parameter level when the switch is locked .
In this case the display shows the abbreviation of the configured controller type.
Confirm the entry and / or move on to next parameter:

press the -key briefly
Settings in detail:
(not available on all types)
Level 1: Invoke: Hold down the - key for more than 5 sec.
until the display changes factory setting: notes:
CH channel selection (no.) for multi-channel controller (only)

*P proportional range Xp (%) (ref. to chapter „Optimization“) 25,0 ___
*I integral action time Tn (min) (ref. to chapter „Optimization“) 7,0 ___
*d rate time Tv (min) (ref. to chapter „Optimization“) 0,2 ___
*Sh sensitivity of response Xsh (%) 0,1 ___
*SA.. switching interval (absolut value) for following (additional) contact no... 5,0* ___
SP.. set point for independent additional contact no... 0,0 ___
*Sd.. switching difference for additional contact no... 3,0 ___
(*201,701/SA3:10,0)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
Level 2: Invoke: Hold down - key and press - key,

y,
hold down both keys for more than 5 sec. until display changes.
Unit switch-over the displayunit (°C / °F) C ___
*bLo/*bHI start / end of display range for voltage- / current -input (only) # ___
*ELo/*EHI start / end of range for external setpoint (only), referring to signal # ___
*SLo/*SHI start / end of range for signal output (only), referring to signal # ___
nSt modification of decimal point characters (0 / 1 / 2) 0 ___
*Lo / *HI start / end of setpoint range (°C /°F or value) # ___
dSPL select display function for lower display (AUS / SP / Y / IST2) AUS ___
(AUS = off, SP = setpoint, Y = output, Ist2 = actual value of channel / measuring input 2)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range
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Optimization Page 5 of 8
1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replaced
by this brief information.
The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;
- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):
lower value= shorter impulse gaps, faster balancing
higher value= longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;
- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):
increases the controller reaction in case of fast actual value or setpoint alterations
(adjust only if necessary). Higher values cause higher increase.
2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjusts
the optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule:
(Parameter-safety-switch on the rear panel of the controller has to be unlocked: position „u“)
Check starting assumptions:
Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:
Lower actual value adequately by manual operation (position of final control element) (quick circuits)
or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).
Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.
During operation the lower display shows: „-Ad-“,
the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilization
of the actual value according to the given controller output (actual value alteration < 0,1% / min),
then it increases the output signal about 10% or, in case of three- point- step controller operation,
it triggers an output impulse with about 10% of the adjusted regulating time.
The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press - key again: Return to manual operation level
eliminate the indicated error
start adaptation again: - key > 5 sec.
or return to operating level: - key shortly
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Catalog
Configuration Page 6 of 8
Access from the operating level.

Unlock the access first: Turn the switch on the rear panel of the controller to position „U“
(= unlocked). It is not possible to configure the controller with locked switch.
(Lock access after the adjustments: Switch position to „L“= locked)
Hold down the - key and press the - key,
y,
hold down both keys for more than 5 sec. until the display changes
Enter the code number (password) ... (1...9999), factory setting: 1

move on to next input: briefly press - key
y
Alternatively: Hold down key after entering code for more than 10 sec.
Possibility to modify code number (optional)
Select control function (type dependent): the displayed ID number for the configured
control function can be changed by pressing the - key..
(Example Type 930K31: choose (92..) 200, 201, 700, 701)
Return to operating level: briefly press the - key

y
or
move on to following adjustments: hold down - key for more than 5 sec.
Note: when switching is continued after a function has been changed, the display will first
flash for several seconds, only then will the controller return to the selected level.
Configurations are displayed in succession (type and design dependent)
and can be changed: ...
(move on to next input: press - key shortly)
factory setting
Ist* correction value to change the controller display (+ / -) 0.0
EinG type of measuring input Pt 100 / DC-signal: „rtd / Iu“ rtd
Ain* type of DC signal for input No.*:rtd/ 0/4-20mA/ 0/2...10V 4...20 mA
(observe different terminal connection I/U) (91..:rtd)
SP 2/E kind of 2nd/ external setpoint: Add/ Sub/ AbS AbS
(adding / subtracting / absolute)
*Y’ ‘ travel time of the actuator „6...600“ (sec.) 60 sec.
*cy’ ‘ switching frequency for 2-point controllers: „2...120“ (sec.) 20 sec.
*out adjusting kind of output signal „0...20/ 4...20(mA)/ 0...10/ 2..10(V)” 4...20 mA
*out adjusting output characteristics direct / inverted „di / in“ in
(for 2 output signals:“in in / in di / di in / di di“)
*td for 2 output signals: deadpoint between output 1 and 2 „0...10%“ 0
AP correction of the output signal operation position 50%
FG A/E automatical adjustment for teletransmitter input (ref. sheet 99ar)
Sou* adjusting type of information signal „0..20/4..20(mA)/0..10/2..10(V)“ 4...20 mA
Sou* adjusting kind of information signal „Ist/Soll..“ (actual/ setp.value) 4...20 mA
(*Sout= signal 1, Sou2= signal 2)
*Y_S behaviour of the output in case of measuring line fault:
relay position:“rel1 / rel2 / AUS“ ( AUS = relays off) rel2(70.),rel1(20.)
continuous output position: „0...100“ (%) 0
reL.. function selection for add. switching contacts :
add. contact 1 (relay-no.*) SoA(701),StA(201)
add. contact 2 (relay-no.*) Su A
select the corresponding measuring input / control circuit CH 1
relay condition in case of measuring line fault: „SiE/SiA“(on/off) Si A
Adr bus adress (adress no.) (for interface equipment only) 5
Return to operating level: briefly press the - key
y again
* = In case of multiple measuring inputs or control loops: relay- or channel number

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The
Catalog
Facilities for Setting Supplementary Contacts Page 7 of 8
Selectable switching functions (depending on version):

For setting please refer to configuration level under „reL...“
Switching functions for trailing contacts: on
off
Sd Sd
LC A Break contact on either side of setpoint SA SA
(Limit comparator). Relay drops out as
deviation increases (Aus = off) on
of f
LC E Make contact on either side of setpoint Sd
SA SA
Sd
(Limit comparator). Relay picks up as

deviation increases (Ein = on) on
of f
Su A Break contact below setpoint. Relay drops Sd
SA
out as actual value decreases (Aus = off)
on
Su E Make contact below setpoint. Relay picks of f

Sd
SA
up as actual value decreases (Ein = on)
on
So A Break contact above setpoint. Relay drops of f
Sd
out as actual value increases (Aus = off) SA
on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd
St A Heating stage below setpoint. Relay on
drops out actual value increases (Aus = of f

Sd
SA actual v alue
off) SP
(s etpoint)
Switching functions for independent contacts: on
of f
US A Relay drops out with increasing actual Sd
value (Aus = off) on
of f
US E Relay picks up with increasing actual Sd
actual value
value (Ein = on) SP
Switching point
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively
Only for units with program option

Pr A Relay switched off (aus) during SP program level, otherwise switched on
Pr E Relay switched on (ein) during SP program level, otherwise switched off
Special function:
SF6 as SoA but switching point at setpoint, control output around SA below
In each case additional settings follow under "rEL." after the selection is acknowledged (P key)
(depending on version):
Ist./ Y assigned value: actual value no. ... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or
assigned setpoint (1SP., rSP, SP.1, ..)
for independent contacts: assignment of parameter input (channel no..)
"Safety" shut down (in case of measuring line fault):
SI E Relay for "Safety" behaviour in event of measuring circuit error: relay on
SI A Relay for "Safety" behaviour in event of measuring circuit error: relay off
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Industry controller 92 E
Technical data Page 8 of 8
Characteristics: stage controller(invers)

Adjustment on parameter level, with lock switch, on
K2 K1
pre adjusted on customer´s demand.
off actual value
(parameters depending on sub type:) Sd2 Sd1
SA2
Proportional band Xp: 0,1...999,9 % SP
Integral action time Tn: 0,0...999,9 min three-point-step-controller (invers)
Rate time Tv: 0,0...99,9 min K1(+) K2(-)
Sensitivity of response Xsh: 0,1...1,0 % on
Travel time of the actuator Tm: 6...600 sec off actual value
Sh
Switching frequency cy: 2...120 sec
SP
Function characteristics: direct / inverted
Switching interval SA (add. contacts): 0..100,0 K continuous controller
Switching difference Sd: 0,1...100,0 K single output double output
Additional contact functions: 100%

in in..
Y1
AP Y2
As switching interval above and below setpoint or 0%
di di..
P ..di
independent adjustable with own setpoint and -100% ..in
P1 td td P2
measuring input, switching function adjustable
I92-d4990419
(ref. to chapter additional switching contacts)
Installation dimensions: Other data:
Housing for panel mounting, 96 x 96 mm (type 92..,
L
93..) or 72 x 144 mm (type 94)
Power supply: 230VAC +/- 10 %, 48...62Hz
B + 0 ,8 alternative 115 VAC, 48 VAC, 24 VAC, 24 VDC
H +0,8 Power consumption: approx. 14 VA
Protective system DIN 40050: IP54 (terminals IP20)
Permissible ambient temperature: 0...60° C
Nominal temperature: 20° C
F o r m 9 6 x9 6 : L = 1 5 0 m m , B = 9 2 m m H = 9 2 m m Climatic category: KUF to DIN 40050
F o r m 7 2 x1 4 4 : L = 1 7 0 m m , B = 1 6 8 m m H = 1 3 9 m m Relative humidity <= 75 % yearly average,
no condensation
EMC: refer to EN 50081-2 and EN 50082-2
Wiring diagram:
(Example, depending on sub type some details can be missed
valid for each delivered controller is the wiring diagram on its casing only)
A927_e59710718
controller electronics
fu s e :
2 4 V :T 0 ,5 A (+) (-)
1 1 5 V :T 0 ,2 A
2 3 0 V :T 0 ,1 A
18V / external digital power control logic signal
40mA analog inputs set value inputs supply output outp. output relay outputs
Ist 3 Ist 4 dig 3 dig 4 Y 2 log 2 Sout 2 Rel 5 Rel 6 Rel 7 Rel 8
7 8 9 10 11 12 23 24 25 26 32 31 37 36 41 31 62 63 64 65 66 67 68 69 70 71 72 73
U+ Ist 1 Ist 2 SPE dig 1 dig 2 Y 1 log 1 Sout 1 Rel 1 Rel 2 Rel 3 Rel 4
99 1 2 3 4 5 6 13 14 15 19 20 21 22 27 28 29 30 31 35 36 40 31 50 51 52 53 54 55 56 57 58 59 60 61
I U L N + + + (protect relay outputs by external fuse 2A)
(L+) (L-)
wiring examples (for input 1 each)
Pt100 standard signal external set value connecting-
3-wire 2-wire 0/4...20mA 0/2...10V 0/4...20mA 0/2...10V example actuator:
a92zu_e49511024
1 2 3 1 2 3 1 2 3 1 2 3 13 14 15 13 14 15 50 51 52 53 54 55
L
+ - + - + - + - M
Auf ~ Zu
N
thermo- feedback standard signal switch- over: optional:
SP active SP2/SPE active power selection 6 7 8 9
couple device incl. feed voltage
1 2 3 1 2 3 99 1 2 3 19 20 19 20 a b c d
- + A S E 1 2 3 4 5
230V optional:
+ - RS 232 / 485
4...20mA Catalog online
115V
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Catalog
7. Pressure control
Type: SPVF 25 K2F 1A 05
Pos.: 7.1
Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Pressure Limiting Valve SPVF
Operating Instructions
Contents
Safety 1
Identification of safety instructions 1
General Safety Instructions 1
Address off Manufacturer 1
The Documentation 2
Description of Operation 2
Installation of the Pressure Limiting Valve 2
Constructions and Spares 3
Commissioning 3
Adjustment 3
Venting 3
Safety
Identification of safety instructions
The safety instructions contained in these operating instructions are identified by the
following attention symbol:
If these instructions are not observed, danger to personnel and equipment can result.
General Safety Instructions

The operating safety of the equipment supplied is only guaranteed under the
prescribed conditions of use (see „Description of Equipment“). The stated limiting
values (see also „Technical Data“) must not be exceeded under any circumstances.
Personnel who are responsible for the installation, operation and the repair of the
pressure limiting valve, must possess an appropriate qualification; this can have been
obtained through training or relevant instruction. Such personnel must be acquainted
with the contents of this instruction.
During all work, the prevailing national regulations relating to accident prevention and
safety in the work place and, where appropriate, internal regulations of the operator,
must be adhered to, even where these are not named in this introduction.
During all work and prior to installation, the connecting pipelines must be de-
pressurised!
The operator must ensure that these operating instructions are accessible to the
personnel concerned at all times.
BSPV-006-01.98-E 1
The Documentation
These operating instructions describe the adjustment and venting of the SPVF pressure
limiting valve. The valve is manufactured in various versions.
The designated version of a particular valve is given on the type reference plate.
Description of Operation
The directly controlled pressure limiting valves are used to protect low pressure circuits, up
to a maximum pressure of 20 bar (SPVF 10, p max 30 bar).
In a cast hydraulic housing 10, a valve spool 30 seals the pressure chamber P from the
reservoir connection T, when acted on by the the pressure spring 70. When the set pressure
is reached, the valve spool 30 opens to create a connection between P and T. As the
pressure in P falls below the set pressure value, the valve closes.
Installation of the Pressure Limiting Valve

The valve should preferably be installed in a vertical attitude, with the adjustment screw
underneath.
Before installing the pressure limiting valve, the pipe work system must be cleaned to
eliminate dirt, scale, sand, swarf, etc. Welded tube, in particular, must be scoured or
scavenged. Cotton rags must not be used in the cleaning operation. The pipelines must be
connected to the valve in an absolutely stress-free condition.
The pipes and connections used must be those appropriate for the operating pressure
range. The pipe manufacturers specifications should be consulted!
On installation, care should be taken that no sealing material finds its way into the pipeline.
Sealing materials such as hemp and mastic are not permissible, since they can lead to
soiling and hence impair the function of the valve.
2 BSPV-006-01.98-E
Constructions and Spares
Item Description Item Description Item Description

10 Housing 50 Protecting cap 100 Vent (bleed)
20 Plug 70 Pressure cap 110 Flat seal
30 Valve spool 80 Threaded rod 120 O-Ring
40 Spring guide 90 Hexagonal nut
Commissioning
Adjustment
The pressure limiting valve is set to the pressure required by the customer. It may be
necessary to carry out a check on the pressure setting during commissioning, since different
flow rates, oil viscosities and pipe lengths can affect the response value. In such cases a
manometer should be connected directly to the valve oil pressure connection. Their
characteristics are such, that each of the four pressure springs available is only suitable for a
limited range of setting pressures.
These pressure ranges are specified in the Spare Parts List 58 601/4.
The pressure setting adjustment is made by removing the protecting cap 50 and loosening
the hexagonal headed nut 90 on the threaded rod 80, by means of an internal hexagon ring
spanner.
Rotation to the right increases the pressure setting, rotation to the left decreases the
pressure. On achieving the desired pressure setting, the hexagon headed nut 90 must be
tightened and the cap 50
Venting
Pressure limiting valves only operate correctly when all the voids within the valve are filled
with hydraulic fluid. If the installed attitude is incorrect, air may collect in the spring chambers
and lead to hydraulic shock. In these circumstances the valve must be ventilated (bled). This
is achieved by unscrewing the vent screw 100 through one turn. Venting should occur at low
pressure and is complete when oil is discharged free of air bubbles. After venting, the vent
screw is tightened again.
Servicing and adjustments to the pressure limiting valve which require it to be dismantled,
are only to be carried out by trained and appropriately qualified personnel.
. When dismantling the pressure limiting valve, the components must be directly protected
from damage and soiling.
Fluids emerging from the valve must be collected and disposed of in such a way that there is
no danger to personnel or to the environment. The currently applicable regulations must be
observed.
BSPV-006-01.98-E 3
8. Instruments and
sensors
Type:
pressure switch
900.2378.905,
diff. pressure switch
920.2377.937
Pos.: 8.1, 8.2

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
9. Heating medium
control
Type: 2/2-way control

valve 421451;
strainer 12050;
float steam trap
CONA SC
Pos.: 9.1; 9.1.4; 9.2, 9.3

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Installation and operating manual B4E
for motor control valves
Installation:
Attention!: - Installation, operation and maintenance should be done only by qualified personnel.
- Disconnect supply before working on the valve.
- It is not permitted to work on the valve body and to exchange the actuator as long as
the valves are subjected to pressure and temperature.
The mounting site should be easily accessible and have sufficient clearance for maintenance
and for removing the actuator. Ensure that the pipe line axes are flush and connection flanges
are parallel. Provide suitable measures to absorb possible tensile and pressure forces.
The valve must not serve as a fixed point. It must be carried by the piping.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through
residual installation material, welding beads or forging scale. If possible, provide a dirt trap
in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is
correct (directional arrows of the flow on the valve housing). Observe a 10 x DN spacing
to flanges, elbows, etc., to avoid an impaired valve function.
Regard the permitted max. operating pressure and temperatur as described in the
corresponding valve specification sheet.
Observe the ambient temperature limits (-20...+60°C), if necessary, provide a drive heater
at lower temperatures, and for higher temperatures insulate the pipeline, provide conductive
plates or cooling possibilities.
Retighten the screws of all flange connections (also lid and connection piece flanges) prior
to commissioning/start-up and following initial heat-up.
Electrical connection:
Check supply voltage according to the rating plate, loosen screws on the motor hood
and remove hood
Route signal and control lines separately from high-voltage lines, if necessary, run in
screened cables. Insert cables (1.5 mm²) through a wringing nipple or cable screw
connection.
Perform electrical connection with the supply voltage switched off according to the
connection diagram (observe VDE and EVU regulations).
In the event of deviations, the connection diagram in the motor hood has precedence
Maintenance:
Following the initial temperature and pressure load, retighten the screws of all flange connections
(also lid and connection piece flanges), the valve cone should be located in the centre.
Attention! Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean and grease lightly in order to protect
stuffing boxes and deflector hoods against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with deflector hoods or bellows.
Undertake maintenance on the drive in accordance with the corresponding information in the
separate operating instructions.
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Telefon 0 52 21/77 08-0
Telefax 0 52 21/77 08-43
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info@KFM-Regelungstechnik
4BA-E.DOC / 0210525
Motor control valve in two way form 421 ... E
PN 16 / 25, GGG-40. Page 1 of 2
Body: GGG-40.3, two way form,

for water and steam,
Pressure range: PN 16, PN 25
Flanges acc. to DIN,
Spindle sealing: spring loaded PTFE-V-ring unit,
for media temperatures up to 250°C
alternatively: graphite-packing
Internal parts: stainless steel
Flow characteristic: equal percentage
Leakage: acc. to VDI/VDE 2174
Actuator: with integrated manual emergency

and load dependent limit switches
Thrust: 2000 N
Power input: 10 VA
alternatively: 4000 N / 20 VA (appendix ..c)
Power supply: 230V /50...60Hz
other voltages on request
Protection class: IP65
Accessories, special types:

Add. signal switches (see page 49e, 49w)
Feedback potentiometer (see page 49f)
Integrated positioner (see page 49sr)
Other voltages (on request)
Other positioning speed (on request)
Reduced kvs-values (on request)
Order text:
Motor control valve PN . ., DN . .
in two way form with PTFE-V-ring unit,
Power supply . . ., List-No. 421 . . .
Max. operating pressure:

by: 120 200 250 °C
PN 16 16 13 13 bar
PN 25 25 20 18 bar
DN List-No. Kvs Stroke Pos. speed Closing pressure (bar)

PN 16 PN 25 m³/h mm sec 2000N 4000N
15 421 400 421 500 4 20 66 25,0
20 421 401 421 501 6,3 20 66 25,0
25 421 402 421 502 10 20 66 25,0
32 421 403 421 503 16 20 66 17,3 25,0
40 421 404 421 504 25 20 66 10,8 25,0
50 421 405 421 505 40 20 66 6,6 16,0
65 421 406 421 506 63 30 100 3,4 9,1
80 421 408 421 508 100 30 100 2,0 5,8
100 421 410 421 510 160 30 100 1,1 3,5

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Telefax 0 52 21/77 08-43 info@KFM-Regelungstechnik
Motor control valve in two way form 421 ... E
PN 16 / 25, GGG-40. Page 2 of 2
153
Space required
Actuator type: 145 to remove
2kN: 4e1230 (for 4kN-actuator: 190) the bonnet
4kN: 4e1430
Bonnet
Motor
Limit switch
Gear
Spring plate-unit H*
Spindle (actuator)
Hand wheel
Mounting rod
PTFE-V-ring-unit
Spindle
Plug
Valve body type: vg21...

L
DN 15 20 25 32 40 50 65 80 100
Height H * 491 505 499 505 511 513 556 557 564
Immersion lenght L 130 150 160 180 200 230 290 310 350
Weight kg 13 14 15 17 18 20 33 37 47
* = add. 45mm for 4 kN-actuator
Electrical wiring: Accessories (optional):

Limit switch Potentiometer Signal switch
M load dependent travel dependent
for valve position
CLOSE OPEN
1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36
N L on 2 = Straightway closes
L on 3 = Straightway opens
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Electric actuator 4e1 B 4e1... E
Operating instructions Page 1 of 2
Attention:
- Adjustment of and work on the actuator may only be done by skilled labour
- Disconnect power supply before removing the cover
- Observe local instructions and terminal diagram
Actuator disassembly: Actuator assembly:

- disconnect supply - lift actuator onto valve connection and secure nuts (18)
- loosen fixing screw (21) (see Fig.1)
(see Fig.1) - tighten (19) coupling nut and fixing screw (21)
- unscrew coupling nut (19) - connect lines acc.to wiring diagram
- unscrew nuts (18) - if necessary, move actuator in both limit positions and
- take off actuator from valve connection adjust stroke indikators (17) on mounting rod
Maintenance: the spindle has to be kept cleen and lubricated, if necessary, lubricate the spindle with
molykote including grease
Limit switches:
Attention! The limit switches work load dependent and turn off automatically when the valve drives in
end position, so that a readjustment, as for travel dependent limit switches, is not necessary
and not allowed. Change of the factory adjustment endangers correct operation, no warranty
will be given and no liability will be accepted in case of damage of the varnish sealing.
If for extraordinary reasons, for instance by previous damages, a readjustment is exceptionally
necessary, the actuator should preferably be sent in for new factory adjustment. Only if this is
exceptionally not possible, a new coarse adjustment can be directly done, with our agreement
and acc. to the following operating instruction.
Special information for actuators with integrated positioner:

No reaction of limit switch can occur when the positioner turns off the actuator to early,
before the valve is in the end position. Don’t readjust limit switch in this case, control
at first adjustment of positioner and correct it if necessary.
Upper limit switch
Add. upper switch

Add. lower switch
Lower limit switch

Lower limit switch
Fig.1

data subject to alteration
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Electric actuator 4e1 B 4e1... E
Operating instructions Page 2 of 2
01
02
03
04
05
06
07
08
09
10
11
12
13
detail X
14
15
16
17
19
20
X
18
Fig.2
No. Designation Part-No.

01 Bonnet: 2kN / 4kN e3h136 / e3h180
02 Motor 230V / 50/60Hz: 2kN / 4kN*** e2m220 / e2m220.4
02a Capacitor: 2kN / 4kN e2k033 / e2k068
03 Gear: pos. speed 3,3s/mm / pos. speed 2,2s/mm e2g1875 / e2g1250
04 Limit switch for spindle position "down" eheo
05 Mounting plate for motor e3zp
06 Terminal bar e6k12
07 Gear wheel e3zr75
08 Mounting plate with wiring diagram e3hb
09 Limit switch for spindle position "up" eheu
10 Base plate e3gp
11 Screw-type cable bushing PG11 e1kv11
12 Spring housing e3fg
13 Set of disc springs e5ft355+e5fs335
14 Spindle e3s
15 Mounting rods e3s... / e3s...n
16 Hand wheel with blocking lever ehhr
17 Stroke indicator e5ak
18 Hexagonal nut M16 e8mv16
19 Coupling nut e5vk
20 Screw collar ring e3sr...
*** = only for standard actuator: voltage 230V / 50/60Hz

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KFM Regelungstechnik GmbH Planckstraße 2 · 32052 Herford catalogue
Operating and installation instructions
Strainer
Contents
1.0 General information on operating 6.0 Putting the valve into operation ..................7
instructions ................................................... 2 7.0 Care and maintenance..................................7
2.0 Notes on possible dangers.......................... 2 8.0 Troubleshooting ............................................8
2.1 Significance of symbols ........................................2
9.0 Troubleshooting table ..................................8
2.2 Explanatory notes on safety information ...............2
10.0 Dismantling the valve or the top part .......9
3.0 Storage and transport ................................. 2
11.0 Warranty / Guarantee ..................................9
4.0 Description .................................................... 3
4.1 Scope of applications ............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks .......................................4
4.5 Marking .................................................................5
5.0 Installation..................................................... 6
5.1 General notes on installation.................................6
5.2 Installing valves with butt weld ends .....................6
Rev. 0040101000 2103 englisch

Strainer
1.0 General information on operating instructions

These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
ATTENTION !
... Warning of general danger.
2.2 Explanatory notes on safety information

In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
Page 2 Rev. 0040101000 2103

Strainer
4.0 Description
4.1 Scope of applications
Strainers are used for "cleanin flowing mediums“.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD
110.
The information complies to the Pressure Equipment Directive 97/23/EC.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles

The medium flows through the strainer screen in the direction shown on the strainer and is
thereby cleaned.
Rev. 0040101000 2103 Page 3

Strainer
4.3 Diagram
rotated
rotated view
view
fig. 1: Strainer - Y fig. 2: Strainer - Y SE
rotated
view
fig. 3: Strainer - Y (1.4408)

Refer to the data sheet for information about materials with designations and figure
numbers.
4.4 Technical data - remarks

for
- Principal dimensions
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
Page 4 Rev. 0040101000 2103

Strainer
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive appendix 2 diagram 6 valves without
safety function are only allowed to bear the CE-marking DN32 onwards.
Rev. 0040101000 2103 Page 5

Strainer
5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
See data sheet for weights.
- Leave sufficient space to remove the screen basket during installation in
pipelines.
- Make sure that the trap is installed to suit the direction of flow.
- Installation position:
a) The screen basket should never be at the top, otherwise the dirt will
fall back into the pipe.
b) If water hammer is possible due to condensation in steam lines,
never install the trap with the screen basket at the bottom, but install
it so that it is horizontal.
- Centre gaskets between the flanges.
- Install compensators to compensate for thermal expansion of the piping.
- Planners / construction companies or operators are responsible for positioning and

installing products.
5.2 Installing valves with butt weld ends

Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
Page 6 Rev. 0040101000 2103

Strainer
6.0 Putting the valve into operation

ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
7.0 Care and maintenance

Maintenance and maintenance-intervals have to be defined by the operator according to
the requirements.
- If necessary, the strainer can be fitted with an additional start-up filter (e.g. filter with
supporting cage) to start up the system.
Depending on the degree of dirt accumulation in the system, the filter must be cleaned
after a system-specific number of service hours.
- Flush the plant thoroughly before starting it.
- The strainer requires little maintenance.
- Strainers must be cleaned when clogging becomes apparent.
General rules concerning cleaning intervals cannot be given because plants vary
considerably in their characteristics.
ATTENTION !
Refer to point 11.0 before dismantling the valve.
- Before reassembling the unit, remember that the bearing surface must be cleaned and a
new gasket (6) must be inserted.
- Set the strainer cover in place.
- Tighten the cover bolts evenly crosswise.
Rev. 0040101000 2103 Page 7

Strainer
Tightening torque‘s for hexagon nuts / bolts:
hexagon nuts / Torque
DN
bolts (Nm)
15- 32 M 10 20-35
40 M 12 20-35
50- 65 M 12 60-80
80-150 M 16 100-125
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.
If malfunctions cannot be eliminate with the help of the following table

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table

ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work!
- read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures

No flow Flange covers have not been removed Remove flange covers
(7, Fig. 3, page 4) (7, Fig. 3, page 4)
Flow too low strainer clogged. Clean/replace screen.
Piping clogged. Check piping system.
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
unit and piping Mating flanges not properly aligned.
Page 8 Rev. 0040101000 2103

Strainer
10.0 Dismantling the valve or the top part

ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.
11.0 Warranty / Guarantee

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.
Rev. 0040101000 2103 Page 9

Ball float steam traps
CONA®SC (PN16 - 25)
for drainage of water from compressed air

with capsule for rapid system start-up and gas systems
PN16 / PN25 PN16 / PN25
- with flanges (series 634....1) - with flanges (series 636....1)
- with screwed sockets (series 634....2) - with screwed sockets (series 636....2)
- with socket weld ends (series 634....3) - with socket weld ends (series 636....3)
- with butt weld ends (series 634....4) - with butt weld ends (series 636....4)
Contents
1.0 General information on operating 5.5.1 Possible installation positions .................. 7
instructions.................................................... 2 6.0 Putting the valve into operation ................... 7
2.0 Notes on possible dangers............................ 2 7.0 Care and maintenance................................... 8
2.1 Significance of symbols ..........................................2 7.1 Cleaning/replacing controller assembly.................. 8
2.2 Explanatory notes on safety information .................2 7.2 Changing the installation position........................... 9
3.0 Storage and transport ................................... 2 7.3 Options ................................................................. 10
4.0 Description...................................................... 3 7.4 Function testing of diaphragm capsule................. 10
4.1 Scope of applications ..............................................3 7.5 Tightening torques.................................................11
4.2 Operating principles ................................................3 8.0 Troubleshooting ............................................11
4.3 Diagram...................................................................4 9.0 Troubleshooting table ................................. 12
4.4 Technical data - remarks .........................................5 10.0 Dismantling the valve or the body ........... 13
4.5 Marking ...................................................................5 11.0 Warranty / Guarantee ................................. 13
5.0 Installation....................................................... 5
5.1 General notes on installation...................................5
5.2 Installation instructions for welding .........................6
5.3 Controller adjustment ..............................................6
5.4 Steam trap testing through ultrasonic
measurement...........................................................6
5.5 Installation position..................................................6
Rev. 0040805003 2404 englisch

CONA®SC - Ball float steam traps

and repair.
ATTENTION !
... Warning of general danger.

In these operating and installation instructions dangers, risks and items of safety
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
to property.

ATTENTION !
- Valves must not be used to take external forces, e.g. they are not designed for
use as climbing aids, or as connecting points for lifting gear.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage.
Do not damage paint protection.
Page 2 Rev. 0040805003 2404

4.0 Description
Series 634: Float-type steam traps with level- and thermal control are used for the drainage
of steam facilities.
Series 636: Float-type steam traps with level control are used for the drainage of systems f
with compressed air or aqueous gases.
ATTENTION !
110.

(refer to Fig. 4 page 9)
The steam trap is controlled by a swivel-mounted ball float (Pos. 24.16).
If condensate is flowing towards the steam trap, the ball float (Pos. 24.16) rises and opens
the discharge valve using the lever mechanism.
In series 634 only (version with diaphragm capsule):
An intercoupled diaphragm capsule (Pos. 24.17) ensures automatic start-up air venting
when cold.
If the amount of condensate decreases or if there is no condensate, the float ball
(Pos. 24.16) falls and shuts the discharge valve.
The compact float ball (Pos. 24.16) exerts level-dependent control on the valve ball
(Pos. 24.4) by means of a lever mechanism. As the level of condensate rises, the valve ball
(Pos. 24.4) is rolled off the valve bore by the lever mechanism, thus opening the valve. The
condensate can now drain away.
If the amount of inflowing condensate is less than the possible valve output or if there is no
condensate flow, the ball float (Pos. 24.16) falls and the valve ball (Pos. 24.4) rolls back
onto the valve bore. The valve is now closed.
If the steam trap is only acted upon by gas, the float ball (Pos. 24.16) remains in equilibrium,
the valve stays shut.
Rev. 0040805003 2404 Page 3

4.3 Diagram
Fig. 1: CONA®SC - series 634 PN16-25

DN15-25
Fig. 2: CONA®SC - series 636 PN16-25

DN15-25
Refer to the data sheet for information about materials with designations and figure numbers.
Page 4 Rev. 0040805003 2404

for
- Principal dimensions,
- Pressure-temperature-ratings, operating limits,
- Valves with different types of connection , etc.
refer to datasheet.
4.5 Marking
AWH Manufacturer
Typ Type
According to the Pressure Equipment Directive appendix 2 diagram 7 valves acc. to article
1 paragraph 2.1.2 (pipes) only show the CE-marking from DN40 onwards.
5.0 Installation
installation work:
ATTENTION !
- The ball float steam trap may be installed for vertical or horizontal flow. Note
installation position with reference to flow, see mark on valve.
avoided.
- Valves must not be used to take external forces, e.g. they are not designed for
use as climbing aids, or as connecting points for lifting gear.
- Precautions against freezing should be taken as a matter of course in any
facilities susceptible to frost. If a system not in operation is in a position
susceptible to freezing, we recommend that the drain plug (Pos. 50) on the
unpressurised steam trap be unscrewed, the residual condensate drained off,
the seal faces cleaned and the plug screwed down again.
The sealing ring (Pos. 49) should be replaced if necessary.
(see Fig. 2 page 4 and item 7.3).
Rev. 0040805003 2404 Page 5

5.2 Installation instructions for welding
(refer to Fig. 1 page 4)
Please refer to the catalogue sheet for information on type and instructions relating to
welding socket weld ends/butt weld ends.
When welding products to the pipeline system they should be adequately cooled to prevent
any adverse effect on the complete controller assembly (Pos. 24) or the flat gasket
(Pos. 17). The heat-affected zone should be restricted to the immediate weld seam area!
Note pre- and post-welding heat treatment in accordance with Material Fact Sheet
DIN EN 10222.
If there are plans to acid clean the facility before putting it into operation, the controllers
(Pos. 24) should be dismantled completely, replaced by acid cleaning inserts, and reassembled
after acid cleaning (refer to 7.1). In such an event please contact the manufacturer.
5.3 Controller adjustment

The controller is manufactured in 3 pressure stages and is not adjustable.
5.4 Steam trap testing through ultrasonic measurement

Testing the operation of the steam trap in the installed state is straightforward with the
“SONACON” function tester.
Refer to data sheet „CONA further components / accessories “.
5.5 Installation position

(refer to Fig. 3 page 7 and Fig. 4 - Fig. 5 page 9)
The float steam trap can be installed for vertical or horizontal flow. This should be stated
when ordering.
If the installation position is not stated it will be supplied for vertical flow (L->R).
It is possible to change the installation position at a later stage (see 7.2).
However, the controller (Pos. 24) must always be installed so that the ball float (Pos. 24.16)
operates in a vertical plane.
Page 6 Rev. 0040805003 2404

5.5.1 Possible installation positions
Horizontal installation:
Inlet from the left side (ZL)
Vertical installation (standard): Horizontal installation:

Inlet from the top Inlet from the right side (ZR)
Fig. 3

ATTENTION !
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
Rev. 0040805003 2404 Page 7


Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work!
- refer to item 6.0 before restarting the plant!
Prior to installation, threads and seal faces should be coated with temperature-
stable lubricant (e.g. “OKS Anti-Seize Paste” white/metal-free for PN16-40 or
“Rivolta” lubricant and parting agent silver for PN63 onwards).
7.1 Cleaning / replacing controller assembly

(refer to Fig. 1 - Fig. 2 page 4 and Fig. 4 - Fig. 5 page 9)
- Dismantle hood (Pos. 16) by slackening cheese-head screw (Pos. 27).
- Remove dirt from body (Pos. 1) and hood (Pos. 16); tiny dirt particles can be removed by
flushing out the ducts and rinsing the body (Pos. 1).
- If necessary dismantle the float controller (Pos. 24) and clean separately or change float
controller.
- Unscrew the hollow-core screw (Pos. 24.10) of the float controller (Pos. 24) from the body
(Pos. 1).
- Pull complete float controller (Pos. 24) out to remove, taking care with the sealing ring
(Pos. 11).
- Check lifting force of ball float (Pos. 24.16) by immersing the whole controller (Pos. 24) in
a water bath. When immersed in the water bath the ball float (Pos. 24.16) must float to the
top. If the ball float (Pos. 24.16) sinks (i.e. goes under) the complete controller (Pos 24)
should be replaced!
Series 634 version with diaphragm capsule only:
- Pull spring clip (Pos. 24.18) off radially and remove diaphragm capsule (Pos. 24.17) from
seat (Pos. 24.19).
- Clean and inspect diaphragm capsule (Pos. 24.17) (see 7.4).
- Form-fit diaphragm capsule (Pos. 24.17) to seat (Pos. 24.19) and push the spring clip
(Pos. 24.18) radially into slot of seat (Pos. 24.19), at the same time pushing the two
angled ends of the spring clip legs (Pos. 24.18) onto the diaphragm capsule (Pos. 24.17).
- Replace the sealing rings (Pos. 17 and Pos. 11).

- Assemble in reverse order (see 7.5).
Page 8 Rev. 0040805003 2404

7.2 Changing the installation position
(see Fig. 1 page 4 - Fig. 2 page 4 and Fig. 3 page 7)
- Position body (Pos. 1) as desired, bearing in mind the direction of flow.
- Remove hood (Pos 16), then slacken hollow-core screw (Pos. 24.10) approximately
1/2 turn.
- Rotate controller (Pos. 24) 90° in the direction required.
- Always fit controller (Pos. 24) so that the ball float (Pos. 24.16) can work in the vertical
plane.
- Tighten hollow-core screw (Pos. 24.10).
- Inspect and if necessary replace body seal (Pos. 17).
- Put on hood (Pos. 16) with drain plug (Pos. 50) pointing down.
- Fit hexagon nuts (Pos. 28) (see 7.5) and tighten crosswise.
Fig. 4: Controller series 634, cpl. Fig. 5: Controller series 636, cpl.
Rev. 0040805003 2404 Page 9

7.3 Options
(refer to Fig. 2 page 4 and Fig. 6 page 10)
ATTENTION !
Escape of hot medium under pressure!
Observe item 2.2!
Accumulated inert gases can be discharged to the

environment with the manual air vent valve (Pos. 51) by
opening the pressure screw (Pos 51.1).
It is possible to return the accumulating gases to the system by
connecting a pressure compensation line to the union
(Pos. 52).
In Series 634 the residual condensate can be drained by way
of the drain plug (Pos. 50) (see 5.1) (standard in Series 636).
Accumulated dirt and condensate can also be removed from
the hood (Pos. 16) using a ball valve (Pos. 56).
During operation it is imperative to observe general working

safety conditions and possibly fit devices to guard against
scalding/injury.
Note section 7.5 when installing and operating the option.
Fig. 6
7.4 Function testing of diaphragm capsule

With a dry, cold diaphragm capsule the diaphragm surface with the circular bead must rest
against the top part of the wall (with 3 knobs), capsule is open (see Fig. 7).
If it rests against the bottom part of the wall, this is a sign that it is defective and must be
replaced with a new diaphragm capsule (see Fig. 8).
It should also be replaced if there are visible deformations on the surface.
top part of wall top part of wall

capsule type capsule type
diaphragm surface bottom part of wall diaphragm surface bottom part of wall
Fig. 7: Capsule OPEN Fig. 8: Capsule CLOSED
Page 10 Rev. 0040805003 2404

7.5 Tightening torques
(refer to Fig. 1 page 4 - Fig. 6 page 10)
Torque (Nm)
Pos. CONA SC PN16-25
DN15-25
24 Controller 60
27 Cheese head screw M10 15
47 Plug 50
50 Plug 50
51 Manual ari vent valve 50
51.1 Pressure screw 30
52 Union for pressur compension line 50
56 Ball valve for blow down valve 50
8.0 Troubleshooting
Instructions.
ATTENTION !
-

Rev. 0040805003 2404 Page 11


ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work!
- refer to item 6.0 before restarting the plant!

No flow Installed in wrong flow direction Fit valve in direction of flow arrow.
Note installation position
Check lifting force; refer to item 5.5.1!
Flange covers not removed Remove flange covers
Ball float (Pos. 24.16) defective Note installation position;
refer to item 7.1
Reduced flow Wrong installation position Note installation position;
refer to item 5.5.1
Correct installation position;
refer to item 7.2
Strainer clogged (Pos. 2) Clean strainer; refer to item 7.1
Piping system clogged Check piping system
Excessive amount of inert gases in Use pressure compensation line option;
system refer to item 7.3
No closure, or internal Controller clogged Clean strainer and controller; refer to
leakage item 7.1
Controller worn out Change controller; refer to item 7.1
Controller incorrectly screwed into body Check seal face between body and
controller, tighten controller correctly;
refer to item 7.5
Controller operated above safe operating Observe operating limits as per data
pressure sheet, i.e. possibly select different
controller
External leakage Hood (Pos. 16) not properly tightened Tighten; refer to item 7.5
with cheese-head screw (Pos. 27)
Flat gasket (Pos. 17) defective Replace sealing;
refer to item 7.1
Page 12 Rev. 0040805003 2404

10.0 Dismantling the valve or the body

ATTENTION !

appointed by us.
Rev. 0040805003 2404 Page 13

10. Valves
Change over valves,

ball valves,
shut-off valves,
non-return valves,
safety valves
Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Change over valves
Type: 776, manual

operated
Pos.: 10.1, 10.2

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Documentation
-Englisch-
Date: 04.06.2004
List of contents
Destignation Page
Data sheet 3-way compact ball valve type 776St 2

Assembly drawing 3-way compact ball valve with limit switch 3
Data sheets limit switch type tiny 4-5
General maintenance for compact ball valve 6
Operating instructions for ball valves 7-9
Pressure-Temperature Rating for ball valves serie 7xx 10
-1-
3-way compact ball valve
steel with L-bore Art. 776St
Technical data
Connection: DIN-flange
Diameters size: DN15 up to DN100
Pressure range: PN16
Temperature range: -20°C up to +160°C
(depending from working pressure)
Application: Chemical-Refinery-Shipbuilding-Plant factory
for media: Water, Oils, Fuels, etc.
Design features:
y TA-Luft certificated y Reduced bore
y 2 ball seats y ISO-bore for automation
T-bore (optional)
e More information on your inquiry!
Dimensions in mm
Pos. Benennung Description Materials Piece

1 Gehäuse Body ASTM A105 1
2 Ring End connection ASTM A105 1
3 Kugel Ball INOX AISI 304 1
4 Kugeldichtung Ball seat PTFE (Teflon) 2
5 O-Ring O-ring FKM (Viton) 1
6 Spindelscheibe Thrust washer PTFE (Teflon) 1
7 O-Ring O-ring FKM (Viton) 1
8 Spindichtung Stem seat PTFE (Teflon) 1
9 Vorspannring Packing gland AVP-9SMNPb36 1
10 Anschlagscheibe End stop INOX AISI 430 (DN15-50) UNI 7070(DN65-100) 2 1
11 Tellerfeder Spring washer UNI 3545 2
12 Mutter Nut UNI 5771 2
13 Spindel Stem INOX AISI 304 1
14 Handhebel Handle UNI 7070 1
15 Flansch Flange ASTM A105 1
DN X Y Z I L R P A C T G M D S E F N B PN Kg
15 89 65 4xM12 20 40 131,5 64,5 47 15,5 9 95 4xØ14 10 76 10 7 32 4xM5 16 2,23
20 99 75 4xM12 20 40 131,5 67 49,5 13,5 9 105 4xØ14 15 82 10 7 32 4xM5 16 2,86
25 109 85 4xM12 23 46 174,5 79 59 18 12,5 115 4xØ14 20 86 12 8 42 4xM5 16 3,89
32 130 100 4xM16 29 58 174,5 84 64 15,5 11,5 140 4xØ18 25 100 12 8 42 4xM5 16 6,21
40 140 110 4xM16 35,5 71 250,5 102,5 78 24,5 13 150 4xØ18 32 105 16 10 50 4xM6 16 8,50
50 160 125 4xM16 41 82 250,5 109 85 25 13,5 165 4xØ18 40 115 16 10 50 4xM6 16 12,27
65 180 145 4xM16 53 106 321,5 128 104,5 28 18 185 4xØ18 50,2 125 20 14 70 4xM8 16 19,10
80 200 160 8xM16 61 122 321,5 136,5 113 28 18 200 8xØ18 64 150 20 14 70 4xM8 16 24,34
100 220 180 8xM16 76 152 381,5 155,5 136 34,5 22 220 8xØ18 76 159 24 18 102 4xM10 16 38,45
-2-
-3-
Plastic-bodied
compact limit switches
Tiny Ti2
Compact design
Protection class IP 65
Mounting measurements according to
DIN EN 50047
Hinged snap lid
q
The switching system for C2 and Ti2 l Compact switches for safety or control
l Small hysteresis on the snap-action applications in protection class IP 65
system l 3 different contact configurations
l Large variety of contact functions available as slow-action or snap-action
l Optimized size utilising proven terminal devices
technology l Positive break p
l Snap-action type prevents undefined l Two channel safety monitoring possible
status even with very slow actuation l Galvanically isolated terminals, type Zb
l Approvals UL, CSA, BG
l Cable entries M 16 x 1.5
l 4 screw terminals M3.5 with self-lifting
clamps
l PBT enclosure, fiberglass reinforced, self-
extinguishing UL 94-V0
l Lid, PA 6.6 UL 94-V0
l 2 mm contact opening of slow-action
system according to EN 81-1 for lift con-
struction Mounting
l Actuator mounting in 4 x 90° a) adjustable mounting with two M4
screws (22 mm centres)
b) fixed positioning with two M5 screws

(23 mm centres) for safety applications
(0.22")
M4 5.5
Slow-action device
M5
(0.16")
(0.08")
4
22
(0.87")
23
(0.91")
Contact configuration
Switching element Switch function Switch contact Designation Voltage Continuous current
Slow-action changeover 1NC/1NO U1Z 250 V 10 A

Snap-action changeover 1NC/1NO SU1Z 250 V 10 A
Slow-action normally-closed 2NC A2Z 250 V 10 A
Snap-action device Snap-action normally-closed 2NC SA2Z 250 V 10 A
Slow-action normally-open 2NO E2 250 V 10 A
Snap-action normally-open 2NO SE2 250 V 10 A
-4-
Plastic-bodied
compact limit switches
Tiny Ti2
Compact design
Protection class IP 65
Mounting measurements according to
DIN EN 50047
Hinged snap lid
Designation Ti2-U1Z w Ti2-SU1Z w Ti2-A2Z w Ti2-U1Z Riw Ti2-SU1Z Riw Ti2-A2Z Riw
Switching diagram
p positive break according to 11 12 13 14 11 12 11 12 13 14 11 12
IEC 947-5-1 Chap. 3
Za: changeover contact is not galvanically isolated 23 24 21 22 21 22 23 24 21 22 21 22
Zb: changeover contact is galvanically isolated p Zb p Zb p Zb p Zb p Zb p Zb
Slow-action contact/snap-action contact l/– –/l l/– l/– –/l l/–
Gasket inside (iw)/outside (w) w w w iw iw iw
Contact travel mm Actuating force N

Tol. ± 0.25 mm Tol. ± 10%
Switching angle Actuating torque Ncm

degree Tol. ± 10%
Tol. ± 3.5°
In Out
Voltage max. 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC

Continuous current max. 10 A 10 A 10 A 10 A 10 A 10 A
Making current, acc. to IEC 947-5-1 AC 15/DC 13 l l l l l l
Switching frequency max. 100/min. 100/min. 100/min. 100/min. 100/min. 100/min.

Mech. operational life – number of switching cycles 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106
Ambient temperature min./max. –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C
–22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F
Approvals UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA
BG BG BG BG BG BG
Weight 0.04 kg 0.04 kg 0.04 kg 0.05 kg 0.05 kg 0.05 kg
Delivery: ex-stock/built to order l/– l/– l/– l/– l/– l/–
Further switching functions
SA2 E2 SE2
11 12 13 14 13 14
21 22 23 24 23 24
Dimensions
All dimensions in mm
-5-
WORK SHEET POS. DESCRIPTION
General maintenance for valves WAFER 1 Body
Operation 1: Loosen the nut (detail 2) 2 End connection
Operation 2: Take fully off the ball (detail 3) 3 Ball
Operation 3: Take the nuts off (detail 12) so as 4 Ball seat
To pull the stem out 5 O-ring
Operation 4: Proceed to the substitution of the 6 Thrust washer
Following details: 4-5-6-7-8 7 O-ring
Operation 5: Clean the body, the ball, the stem and 8 Stem seat
The end connection (details 1-3-13-2) 9 Paking gland
Before reassembling the valve 10 End stop
Operation 6: Assemble the thrust washer (detail 6) 11 Spring washer
And the ring (detail 7) in the stem 12 Nut
(detail 13) 13 Stem
Operation 7: Assemble the stem (detail 13) inside 14 Handle
The body (detail 1) and then assemble
The details 8-9-10-11-12-14
Operation 8: Assemble the ball and the ball seat
(details 3-4) inside the assembled body
Operation 9: Put the o-ring (detail 5) on the end
Connection (detail 2) and the ball seat
(detail 4) in the end connection (detail 2)
Operation 10: Assemble the end connection (detail 2)
In the body (detail 1) and screw it on
Until it stops metal to metal
-6-
Operating, Montage and Maintenance
Recommendation for Ball Valves TA 7
1. General:
y When making inquiries or spare part orders please always quote our order no. and, if possible, the ball
valve type and year of manufacture.
y We assume no liability in cases of disregard of operating or safety instructions or of faulty installation
or maintenance.
y Please refer to all data on further automation equipment such as drives, actuators, electrovalves, limit
switches etc.
y Unfortunately, we are unable to take back customer-specific valves.
2. Safety instructions:
y Maintenance, assembly and repair work may only be carried out by duly authorised and qualified
personnel.
y 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.
y These operating instructions do not replace any national accident prevention regulations or local
safety regulations; they are invariably subordinate to these.
y Observe the following before carrying out any repair or maintenance work:
e always turn off the power supply of the drives before carrying out repair or maintenance work
(danger of bruising!)
e make sure that no-one puts the plant into operation
e evacuate the pipe, prevent pressure build-up or retention
e inform yourself on possible dangers emanating from residues of operating material; wear safety
gloves and goggles etc. as necessary
e let valves cool off if necessary
e ensure that limit values relating to pressure, temperature and the operating material are
not exceeded
3. Transport:
y Valves should be transported to the building site in a firm packing.

y Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage.
y Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been.
4. Storage:
y 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.
y Valves that are not needed immediately should be fitted with a protective cap and stored in a well-aired,
dry room.
-7-
5. Functioning:
y Ball valves serve as shut-off devices in plants, where they are screwed or welded into the pipe system.
y 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.
6. Installation:
y The piplines must be cleaned or flushed before installation, so that any residues and foreign bodies do not
get into the ball valves.
y 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.
y Lead the piplines free of stress up to valve to be installed.
y Ensure that the ball valves are in their open position.
y Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange screws in
opposite directions with the appropriate torque.
y Protect the interior parts of the valve before carrying out any welding (observe maximum tolerable
temperature of gasket!).
7. Initial operation:
y Read and ensure compliance with all operating instructions and check that operating conditions are as
required and the valves has been installed correctly.
y Flush the piping with valves fully opened before testing their function.
y After completing the installation and before putting the valve into operation, check that it works properly
by opening and closing it several times.
y Make sure that the valve works perfectly and that it turns in the right direction.
8. Maintenance:
y The ball valves are designed so that when used as intended no maintenance work at all is required over a
period of 3 years.
y 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.
y It is advisable to check the flange and selector shaft packing for leakage after prolonged operation.
-8-
9. Troubleshooting:
e 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.
e 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!
-9-
Druck-Temperatur-Diagramm für Kugelhähne Serie 7xx
Pressure-Temperature Rating for ball valves serie 7xx TA 5
-10-
Ball valves
Type: V3NBC-316,
V1-316-299

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
KUWO GmbH
Hägerstrasse 22, D-27321 Thedinghausen
Werkstrasse 226, D-19061 Schwerin
Operating, installation 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-
KUWO GmbH
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,
solenoid valves, 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-
KUWO GmbH
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
handle clockwise. They are not intended for throttling or regulating the flow of medium,
and intermediate positions are therefore not permissible.
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 compressed 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.
- Protect the interior parts of the valve before carrying out any welding (observe maximum
tolerable temperature of gasket!).
-3-
KUWO GmbH
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 possible 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-
Shut-off valves
Type: 1200600…

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Stop valve with gland seal
STOBU®
Contents
1.0 General information on operating 5.4 Installing valves with limit switches ...................... 7
instructions .................................................. 2 6.0 Putting the valve into operation ................ 8
2.0 Notes on possible dangers......................... 2 7.0 Care and maintenance................................ 8
2.1 Significance of symbols ........................................2 8.0 Troubleshooting .......................................... 10
2.2 Explanatory notes on safety information ...............2 9.0 Troubleshooting table ................................ 11
3.0 Storage and transport ................................ 2 10.0 Dismantling the valve or the top part ..... 12
4.0 Description................................................... 3 11.0 Warranty / Guarantee ................................ 12
4.1 Scope of applications ............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks .......................................5
4.5 Marking .................................................................5
5.0 Installation.................................................... 5
5.1 General notes on installation.................................5
5.2 Installing valves with butt weld ends .....................6
5.3 Installing valves with balancing plugs .................7
Rev. 0040102000 2103 page 1

STOBU®

and repair.
ATTENTION ! Warning of general danger.
...

In these Operating and Installation Instructions dangers, risks and items of safety
Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
to property.

ATTENTION !
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
Page 2 Rev. 0040102000 2103
STOBU®
4.0 Description
Valves are used for „shut-off and/or throttling of media“.
ATTENTION !
110.

The valve is closed by turning the hand wheel clockwise (valve plug/seating function).
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
The valve spindle is sealed by a bellow and an outer safety stuffing box.
Tighten the stuffing box if required.
Rev. 0040102000 2103 Page 3

STOBU®
4.3 Diagram
rotated
view
rotated
view
rotated
rotated view
view
fig. 1: STOBU straight through 1.0619+N fig. 2: STOBU angle pattern 1.0619+N
rotated
view
rotated
view
rotated
view
rotated
view
fig. 3: STOBU straight through fig. 4: STOBU-straight through

GG-25/GGG-40.3 shoed butt weld ends 1.0619+N
Refer to the data sheet for information about materials with designations and figure
numbers.
Page 4 Rev. 0040102000 2103

STOBU®
for
- Principal dimensions
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer
Typ Type
According to the Pressure Equipment Directive appendix 2 diagram 6 valves without
safety function are only allowed to bear the CE-marking DN32 onwards.
5.0 Installation
installation work:
ATTENTION !
- Note installation position with reference to flow, see mark on valve.
avoided.
- Valves can be installed with the spindle pointing in any direction, but the
prefered spindle position is vertical.
- Valves should be installed upside down only, if the medium being handled is
clean.
- Keep the thread and shaft of the spindle free from paint.
Rev. 0040102000 2103 Page 5

STOBU®
- Lockable stop valves must be installed in such a way that the spindle is vertical
and the flow agent enters under the taper. If the valves are installed in pipelines
in positions other than specified, they must be fitted with a closing spring.
- Design with loose plug
A plug damper should be used in critical applications, immediately downstream
of pumps, compressors, etc., where severe turbulence and pulsating pressure
surges may occur.
Through the damper function of the loose plug, the negative influence of
pressure shocks and high turbulences, are not transferred onto the valve.

5.2 Installing valves with butt weld ends

Refer to the data sheet for information about the shape of the butt weld ends.
Page 6 Rev. 0040102000 2103

STOBU®
5.3 Installing valves with balancing plugs
ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if the
differential pressures listed in the table below are exceeded in the closed state.
Valves with pressure balancing plugs should be installed so that the pressure of
the medium acts on the plug ( 3).
ATTENTION !
Note direction of flow.
fig. 5
Valves with pressure balancing plugs have to be installed with medium flowing over the
plug (3) as indicated by flow direction arrow on valve body.
Working principles:
When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug (3.1)
off the larger balancing plug (3). This allows the medium to pass through the plug and
equalizes the pressure of the medium under the plug (3). After the pressures have been
equalized within the values stated in the table below, the valve can be opened by turning
the valve further.
Balancing plug DN 125 150 200 250 300 350 400 500
Pressure difference ∆P 25 bar 21 bar 14 bar 9 bar 6 bar 4,5 bar 3,5 bar 1,5 bar
- Pressure balancing plugs are fully effective only in closed line section.
- The pressures of the medium on either side of the plug cannot be equalized if the medium
is discharged into “open air”.
- If adequate pressure equalisation cannot be achieved using a pressure balancing plug,
other design solutions must be used instead (e.g. a bypass line).
5.4 Installing valves with limit switches

The valves with limit switches must be connected up as shown in the plans of the plant on
the basis of their working principles.
Rev. 0040102000 2103 Page 7

STOBU®

ATTENTION !
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media

Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
fig. 6: Pattern with hinged bolts

- Observe safety instructions!
- Keep the spindle well greased!
Page 8 Rev. 0040102000 2103

STOBU®
- Lubricant: e.g. Klüberpaste HEL 46-450 (at valves for oxygen: Oxigenoex FF 250)
to order at: Klüber Lubrication München KG, Postfach 701047, D-81310 München
or a lubricant wich is suitable for the application.
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
- If the valve spindle (4) leaks, gradually tighten the stuffing box seal (6) evenly in
increments by means of the hex. nuts (19) until leaking stops.
ATTENTION !
- Retighten the stuffing box packing if required and re-pack it in good time.
- For safety reasons we recommend that valves only be repacked when
depressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
- Replace stuffing box packings only after the system has cooled down and the pressure in
the plant has been relieved.
In the case of corrosive or aggressive mediums, drain and ventilate the valve before
replacing the packing.
- Valve service life can be improved by leakage checks.
- When cutting the new packing from the roll,

make sure that the ends are cut with a slant
fig. 7: Split packing ring

Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and 2
new gaskets (9) must be inserted.
- Set the cover in place
- Tighten the hexagon nuts (hexagon screws for valves of cast iron) evenly crosswise.
- Tightening torque‘s for hexagon nuts / screws:
DN hexagon nuts / Torque

hexagon screws (Nm)
15- 32 M 10 15-30
40- 65 M 12 35-50
80-100 M 16 75-100
125-150 M 16 80-120
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
Rev. 0040102000 2103 Page 9

STOBU®
8.0 Troubleshooting
Instructions.
ATTENTION !
-

Page 10 Rev. 0040102000 2103

STOBU®

ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work!
- read point 6.0 before restarting the plant !

No flow Valve closed. Open valve.
Flange covers not removed. Remove flange covers.
(25; fig.1-2; page 4) (25; fig.1-2; page 4)
Little flow Valve not sufficiently open. Open valve.
Dirt sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Valve difficult to move or Spindle (4) dry (fig. 6; page 8) Grease spindle (4) (fig. 6; page 8)
cannot be opened (Lubricant: see page 9)
Stuffing box too tight (6; fig. 1-4; page Slacken hex. nuts of stuffing box gland
4) (15) slightly, but not sufficiently to
cause leakage (fig. 1-4; page 4)
Wrong direction of rotation Turn in correct direction (anticlockwise
to open valve).
Valve spindle leaking Stuffing box gland (15) slack Tighten stuffing box gland (15) until
(fig. 1-4; page 4). leakage stops.
-Hex. nut (fig. 1-4; page 4).
If necessary, renew packing in stuffing
box seal (6). Observe warnings (Fig. 6;
page 8)!
Leakage across valve Valve not properly closed. Pull hand wheel tight without tools.
seat. Seat (1.2) / plug (3) damaged by for- Replaced valve, consult supplier/man-
eign particles. ufacturer.
(fig. 1-4; page 4).
Pressure difference too high. Use a valve with balancing plug
(see point 5.3).
Medium contaminated (suspended sol- Clean valve.
ids). Install dirt screen upstream of valve.
Valve with throttling plug + Locking device has been tightened. Release locking device.
position indicator + lock-
ing device cannot be
opened.
Rattling / banging Nominal diameter of the valve in com- Choose smaller nominal diameter
of the plug design with pliance to the flow rate is to big Use a plug damper execution: see
„loose plug“ medium
- high flow turbulences; Alter the system
- the valve with loose plug is mounted Use a plug damper execution: see
directly by a centrifuged pump; medium
- behind pressure reduction stations;
- behind pipe elbows;
- in compact plants;
- expansion joints are missing;
- the pump is not mounted on a
damper;
- there is no flow stabilizing pipe length;
- there is no start-up bypass line
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
valve and piping. Mating flanges not properly aligned.
Rev. 0040102000 2103 Page 11

STOBU®
10.0 Dismantling the valve or the top part

ATTENTION !
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.

appointed by us.
Page 12 Rev. 0040102000 2103

Non-return valves
Type: SR 20.40 St
Pos.: 1.1.4, 1.2.4, 1.3.4, 1.4.4, 4.1.8

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Instruction Manual
Wafer Type Check Valves
SR / HSR...
ZRK / ZRL...
ZRD...
1
Content
1. Declaration of Conformity in acc. to PED 97/23/EC 3

1.1 Declaration of Conformity SR/HSR, ZRK/ZRL 3
1.2 Declaration of Conformity ZRD 4
2. General Notes 5
3. Intended Use 5
4. Safety Instructions 5
4.1 General safety instructions 5
4.2 Qualification of personnel 5
4.3 Safety instructions for the operator 5
4.4 Special dangers 6
5. Transport and Storage 6
6. Categorisation in acc. to PED 97/23/EC 7
7. Specification 8
7.1 Marking 8
7.2 Drawings and parts lists 8
7.3 Functionality 10
8. Installation 10
8.1 General information 10
8.2 Operational characteristics 10
8.3 Range of applications 11
8.4 Installation instructions 12
9. Initial Operation, Shut down, Maintenance, Elimination of Failures 13

9.1 Initial operation 13
9.2 Shut-down 13
9.3 Maintenance 13
9.4 Elimination of failures 14
10. Spare Parts 14
11. Further Information 14

This instruction manual contains important safety instructions. Please read carefully before installation and initial
operation. It is hardly recommended to keep this manual within the operation area.
2
1.1 Declaration of Conformity
in acc. to Pressure Equipment Directive 97/23/EC
Description of the Pressure Equipment
Type DN PN Module Type DN PN Module Type DN PN Module Type DN PN Module

SR10.16 125-200 6-16 A SR12.16 65-200 6-16 A ZRK4 65-200 6-16 A ZRL4 65-200 6-16 A
SR60.06 32-100 6 A SR70.16 65-100 6-16 A ZRK1 50-100 10-40 A1 ZRL1 50-100 10-40 A1
SR61.06 32-100 6 A ZRK1S 50-100 10-40 A1 ZRL1S 50-100 10-40 A1
SR20.40 32-100 6-40 A1 SR33.40 32-100 6-40 A1 ZRK2 50-100 10-40 A1 ZRL2 50-100 10-40 A1
SR20.40St 32-100 6-40 A1 SR34.40 32-100 6-40 A1 ZRK3 50-100 10-40 A1 ZRL3 50-100 10-40 A1
SR22.40 32-100 6-40 A1 SR35.40 32-100 6-40 A1 ZRK4 250,300 6-16 A1 ZRL4 250,300 6-16 A1
SR30.40 32-100 6-40 A1 SR55.40 32-100 6-40 A1 ZRK5 50-100 10-40 A1 ZRL5 50-100 10-40 A1
Sr31.40 32-100 6-40 A1 HSR20.160 32-100 63-160 A1
SR32.40 32-100 6-40 A1 HSR30.160 32-100 63-160 A1 ZRK1 125-600 10-40 H ZRL1 125-600 10-40 H
SR40.40 32-100 6-40 A1 SR50.40 32-100 6-40 A1 ZRK1S 125-600 10-40 H ZRL1S 125-600 10-40 H
SR20.40 125-200 6-40 H SR30.40 125-200 6-40 H ZRK2 125-600 10-40 H ZRL2 125-600 10-40 H
SR20.40ST 125-200 6-40 H SR34.40 125-200 6-40 H ZRK3 125-600 10-40 H ZRL3 125-600 10-40 H
SR22.40 125-200 6-40 H SR35.40 125-200 6-40 H ZRK4 350-600 6-16 H ZRL4 350-600 6-16 H
SR25.40St 250-350 6-40 H SR55.40 125-200 6-40 H ZRK5 125-600 10-40 H ZRL5 125-600 10-40 H
All valves in size DN £25 comply with article 3, paragraph 3 and are not permitted to be marked
neither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH Hamburg

Mönckebergstrasse 27
20095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of
these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
No harmonized standards available at present
Other Applied Standards and Technical Rules

AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
22.01.2002 Herfried Schrader

Date Authorized Subscriber
3
1.2 Declaration of Conformity
in acc. to Pressure Equipment Directive 97/23/EC
Description of the Pressure Equipment
Type DN PN Module Type DN PN Module

ZRD G/K3 65 - 200 6 - 16 A ZRD G/API594 21/2" - 6" Class125, 150 A
ZRD G4/K3 65 - 200 6 - 16 A ZRD G4/API594 21/2" - 6" Class125, 150 A
ZRD 4/K3 65 - 200 6 - 16 A ZRD 4/API594 21/2" - 6" Class125, 150 A
ZRD 6/K3 65 - 200 6 - 16 A ZRD 6/API594 21/2" - 6" Class125, 150 A
ZRD G/K3 250, 300 6 - 16 A1 ZRD G/API594 8", 10" Class125, 150 A1
ZRD G4/K3 250, 300 6 - 16 A1 ZRD G4/API594 8", 10" Class125, 150 A1
ZRD 4/K3 250, 300 6 - 16 A1 ZRD 4/API594 8", 10" Class125, 150 A1
ZRD 6/K3 250, 300 6 - 16 A1 ZRD 6/API594 8", 10" Class125, 150 A1
ZRD 1/K3 50 - 100 6 - 40 A1 ZRD 1/API594 2" - 4" Class150, 300 A1
ZRD G/K3 350 - 600 6 - 16 H ZRD G/API594 12" - 24" Class125, 150 H
ZRD G4/K3 350 - 600 6 - 16 H ZRD G4/API594 12" - 24" Class125, 150 H
ZRD 4/K3 350 - 600 6 - 16 H ZRD 4/API594 12" - 24" Class125, 150 H
All valves in size DN £25 comply with article 3, paragraph 3 and are not permitted to be marked
neither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH Hamburg

Mönckebergstrasse 27
20095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of
these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
No harmonized standards available at present

Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
22.01.2002 Herfried Schrader

Date Authorized Subscriber
4
2. General Notes
This instruction manual applies to the above mentioned valves which are subject to
the Quality Management System Standard acc. to DIN/ISO9001 in both the manner
of manufacturing as well as testing and which do meet the basic safety requirements
of Annex I of the Pressure Equipment Directive 97/23/EC. This instruction manual is
intended to support the user of above mentioned valves in installation, operation and
maintenance.
Disregarding the following caution advices could evoke

dangerous situations which entail an inefficacy of the manufacturers’
Attention warranty.
For any questions, please contact the manufacturer and also see
chapter 11.
3. Intended Use
Wafer type check valves are solely destined for installation within a pipeline system
in consideration of the admitted pressure and temperature limits to avoid a backflow
of the media.
It is the operators’ responsibility to examine the chemical resistance in relation to the
specified operation data.
All valid operation data are indicated in chapter 8 respectively in the technical data
sheets of the relevant types.
4. Safety Instructions
4.1 General Safety Instructions
Those safety regulations applying to the pipeline system apply to the valves itself
accordingly, i. e. any national or international rules for accident prevention as well as
possibly existing operators’ working-, production- and safety regulations have to be
considered. This instruction manual only points to those safety instructions which
have to be considered additionally.
4.2 Qualification of Personnel
Only qualified staff is permitted to install and maintain the valves. The operator is
obliged to coordinate the competencies, the responsibilities and the surveillance of
his staff. Should the staff not have the necessary knowledge, the operator must
provide adequate additional training. The operator has to ensure that the content of
this instruction manual is comprehended in all its particulars.
4.3 Safety Instructions for the Operator
Due to the fact that the following points are not in the responsibility of the valve
manufacturer the operator has to ensure when using the valves that
· the valves are solely used in the way described in chapter 3
· the pipeline system is installed in a professional manner. The wall thickness of
the valve body is designed in a way that tensions which do exist within the
pipeline system are considered in a usual order of magnitude.
· the valves are properly installed between the flanges.
5
· an usual flow rate within the pipeline system is not exceeded during a
continuous operation. For abnormal service conditions, e. g. oscillation, water
shock, cavitation or a medium that contains larger solid particles, please
contact RITAG for clarification.
· the valves are protected against touch when working at a temperature
<0°C respectively >40°C.
Prevention from misusing the valves:

It has to be particularly ensured that the selected body materials and
inner parts of the valve are suited for the medium that is used. The
manufacturer assumes no liability for any damages caused by
Danger aggressive media.
Disregarding this precaution may evoke dangerous situations for
the operating personnel or cause damages to the pipeline system.
4.4 Special Dangers
Before disassembling the valve the pipeline has to be depressurized,

the pipe has to be totally drained and released. Afterwards the flange
screw connections can be unscrewed and the valve can be
Danger to dismantled.
Life Misusing this precaution means danger to the life of the
operating personnel.
5. Transport and Storage
The valves are provided ready for installation. They need to be treated, conveyed
and stored carefully.
· Those valves that are delivered with a protecting packing need to be stored
within this packing up to the moment of installation.
· In case of a direct storage at the installation location the valve has to be stored
in a closed room and has to be protected against any damaging impacts.
· It is recommended to use up any stock items first in order to achieve short
storage periods.
· Those valves that are equipped with a soft sealing need to be protected
against sunlight that might hit this soft sealing or any other UV-radiation in
order to avoid ageing.
· Lifting tools for transport are only to be fastened on the valve body. Inner parts
may not be misused as „carrying devices“.
6
6 Categorisation in acc. to PED 97/23/EC article 9
Wafer Type Lift Check Valves Type SR / HSR

CE-marking in conjunction with declaration of conformity in acc. to PED 97/23/EC
Nominal Diameter
Valve type PN Fluid group 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
SR10.16 16 2 * * * * * * CE CE CE * * *
SR12.16 16 2 no CE no CE no CE CE CE CE CE CE CE * * *
SR70.06K 6 2 no CE no CE no CE no CE no CE no CE * * * * * *
SR70.16 16 2 no CE no CE no CE CE CE CE * * * * * *
SR60.06 6 1 u. 2 CE CE CE CE CE CE * * * * * *
SR20.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR20.40St 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR25.40 40 1 u. 2 * * * * * * * * * CE CE CE
SR31.40 40 1 u. 2 no CE CE CE CE CE CE CE CE CE CE * * *
HSR20.160 160 1 u. 2 CE CE CE CE CE CE * * * * * *
HSR30.160 160 1 u. 2 CE CE CE CE CE CE * * * * * *
* not available in this size
Wafer Type Swing Check Valves Type ZRK / ZRL

Nominal Diameter
Valve type PN Fluid group 50 65 80 100 125 150 200 250 300 350 400 450 500 600
ZRK1, ZRL1, ZRK5 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRK1-S, ZRL1-S 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRK2, ZRK3 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRK4 10 2 no CE no CE no CE keinCE CE CE CE CE CE CE CE CE CE CE
16 2 no CE CE CE CE CE CE CE CE CE CE CE CE CE CE
Wafer Type Duo Check Valves Type ZRD

Nominal Diameter
Valve type PN Fluid group 50 65 80 100 125 150 200 250 300 350 400 450 500 600
ZRD1/K3,ZRD2/K3, 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD3/K3 16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD1/API594, 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD2/API594, 16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD3/API594 25 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD G/K3,ZRD G4/K3 6 2 no CE no CE no CE no CE no CE no CE CE CE CE CE CE CE CE CE
ZRD4/K3, ZRD6/K3 10 2 no CE no CE no CE no CE CE CE CE CE CE CE CE CE CE CE
16 2 no CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD G/API594, 6 2 no CE no CE no CE no CE no CE no CE CE CE CE CE CE CE CE CE
ZRD G4/API594, 10 2 no CE no CE no CE no CE CE CE CE CE CE CE CE CE CE CE
ZRD 4/API594, 16 2 no CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD 6/API594
The conformity in acc. to PED 97/23/EC is documented by the CE-marking on the

valve body.
7
7 Specification
The sectional drawings shown in this chapter do exemplary illustrate the basic design
of the valves. Detailed information can be found in the technical data sheet of the
specific valve type.
7.1 Marking
All valves are marked in acc. to PED 97/23/EC, TRB 801 No. 45 or EN19.
General Marking
Manufacturer RITAG
Valve type ...
Nominal diameter DN...
Nominal pressure PN..
Material ...
Batch no. (retraceability of the material) ...
Year of manufacture (month, year, e.g. 5.02) ...
Arrow of flow direction
CE-marking (starting from category I, see chapter 1 u. 6) CE
Code of the Notified Body (Module A1 und H) 0525
Stamp of inspector ...
Further special markings, e. g. plant identification code or project name could be

additionally affixed on request.
7.2 Drawings and Parts Lists
Lift Check Valves
SR35.40,SR40.40, SR50.40, SR55.40, SR20.40, SR20.40St, SR22.40, SR70.06, SR70.16,

HSR20.160, HSR30.160 SR30.40, SR31.40, SR32.40
SR33.40, SR34.40, SR12.16
Item no. Denomination Item no. Denomination

1 Body 2 Plate/disc
3 Sealing (spare part) 4 Guide plate
5 Spring (spare part ) 6 Guide screw
7 Centering ring
8
Swing Check Valve
No spring illustrated
1 Body 7 Hinge (left)

3 Plate 8 Screw
4 Sealing (spare part) 9 Ring
5 Hinge pin 10 Eye screw
6 Hinge (right) Spring (spare part)
Duo Check Valve
1 Body 8 Pin retainer

2 Plate 9 Ring
3 Shaft 10 Stop pin
4 Sealing (spare part) 11 Eye bolt
5 Spring (spare part) 12 Set screw
6 Packing (spare part)
7 Ring
9
7.3 Functionality
Wafer type non-return valves are valves which are controlled by the backflow of the
medium. The obturator (disc, cone, plate) is first lifted and then opened by the flow.
In the event of an incipient backflow (e. g. failure of a pump) the obturator closes self-
controlled by its dead weight. This closing process can optionally be supported by
using a spring.
8 Installation
8.1 General Information
Positioning within the isometry of the pipeline as well as a proper installation of the
valves is basically the responsibility of the engineer or the operator. Any faults in
engineering or installation could cause misfunction of the valves and constitute a
significant danger.
For the installation of the valves the same safety regulations are to be considered as
for connecting pipelines and its components.
Pipelines have to be laid in such a manner that shearing strain and

bending stress are not able to affect the valve body. The flange
Attention facings have to be in a parallel position to each other. The facings
need to be clean and undamaged.
Valve bodies in material cast iron EN-JL1040, EN-JS1030 must not
be treated by sudden pressure (e. g. hammer blow) because
Danger components may be destroyed.
Valves working at temperatures <0°C respectively >40°C need to be
protected against touch.
8.2 Operational Characteristics
Wafer Type Lift Check Valves Type SR/HSR

Operating data for SR - valves
permissible working temperature (°C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN permissible working pressure (bar)
SR10.16 EN-JL1040 16 16 16 14,4 12,8 11,2 9,6
SR60.06 PTFE 6 6 6 5 4
SR12.16 CC483K 16 16 16 15 14 13
SR70.16 2.0401 16 16 16 15 14 13
SR20.40 1.4021 40 40 40 37,5 35 32,5 30 27,5 25
SR20.40St bis DN100 1.0570 1E1 40 40 40 36 33 29 24
SR20.40St DN125 bis 200 1.0421 40 40 40 36 33 29 24
SR25.40 1.0421 40 40 40 36 33 29 24
SR22.40 1.0460 40 40 40 36 33 29 24 20 16
SR30.40 1.4571 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
SR31.40 3.7035 40 40 40 34 28 22 16
SR32.40 2.4617 40 40 40 38 36 34 32 30 28
SR40.40 1.0460 40 40 40 37 35 31,5 29 27 26 23
SR33.40 2.4610 40 40 40 38 36 34 32 30 28
SR34.40 1.4301 11EO 40 34,7 27,9 25,2 22,6 21 19,6 18,5 17,4 16,9 16,4
SR35.40 1.0460 40 40 40 37 35 31,5 29 27 26 23
SR55.40 1.4571 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
HSR20.160 1.0460 160 160 160 145 130 125 100 84 68 53
HSR30.160 1.4571 15EO 160 160 154 148 142 136 130 124 118 110 102
SR50.40 1.4571 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
10
Wafer Type Swing Check Valves Type ZRK/ZRL
Operating data for ZRK / ZRL - valves
admissible working temperature (°C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN admissible working pressure (bar)
ZRK1, ZRL1,ZRK1-S, ZRL1-S 1.0570 1E1 10 10 10 9 8 7 6
1E1 16 16 16 14,4 12,8 11,2 9,6
1E1 25 25 25 22,5 20 17,4 15
1E1 40 40 40 36 33 29 24
ZRK2, ZRL2 1.4301 11EO 10 8,7 7 6,3 5,6 5,2 4,9 4,6 4,4 4,2 4,1
11EO 16 13,9 11,2 10,1 9 8,4 7,8 7,4 7 6,8 6,5
11EO 25 21,7 17,4 15,8 14,1 13,1 12,2 11,6 10,9 10,6 10,2
11EO 40 34,7 27,9 25,2 22,6 21 19,6 18,5 17,4 16,9 16,4
ZRK3, ZRL3 1.4571 15EO 10 9,3 8,2 7,9 7,4 7 6,4 6,2 6 5,8 5,7
15EO 16 14,9 13,2 12,6 11,9 11,2 10,3 10 9,6 9,3 9,2
15EO 25 23,3 20,6 19,7 18,6 17,4 16,1 15,6 15 14,6 14,3
15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
ZRK4, ZRL4 CC483K 10 16 16 15 14 13
16 16 16 15 14 13
ZRK5, ZRL5 1.0425 3EO 10 10 10 9,8 9,5 9 8 7 5,5
3EO 16 16 116 15,7 15,2 14,4 12,8 11,2 8,8
3EO 25 25 25 24,5 23,8 22,5 20 17,5 13,8
3EO 40 40 40 39 38 36 32 28 22
Lowest working temperature: ZRK1, ZRL1, ZRK4, ZRL4, ZRK5, ZRL5 minus 10°C; ZRK2, ZRL2, ZRK3, ZRL3 minus 200°C
Wafer Type Duo Check Valves Type ZRD

Operating data for ZRK / ZRL - valves
permissible working temperature (°C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN permissible working pressure (bar)
ZRD G/K3, ZRD G4/K3 EN-JL1040 * 6 6 6 5,4 4,8 4,2 3,6
ZRD 6/K3 EN-JL1040 * 10 10 10 9 8 7 6
EN-JL1040 * 16 16 16 14,4 12,8 11,2 9,6
ZRD 4/K3 CC483K 6 6 6 5 4 3
CC483K 10 10 10 9 8 7
CC483K 16 16 16 15 14 13
ZRD 1/K3 1.0619 3EO 10 10 10 9,8 9,5 9 8 7 5,5
1.0619 3EO 16 16 116 15,7 15,2 14,4 12,8 11,2 8,8
1.0619 3EO 25 25 25 24,5 23,8 22,5 20 17,5 13,8
1.0619 3EO 40 40 40 39 38 36 32 28 22
ZRD 2/K3 1.4308 11EO 10 8,7 7 6,3 5,6 5,2 4,9 4,6 4,4 4,2 4,1
1.4308 11EO 16 13,9 11,2 10,1 9 8,4 7,8 7,4 7 6,8 6,5
1.4308 11EO 25 21,7 17,4 15,8 14,1 13,1 12,2 11,6 10,9 10,6 10,2
1.4308 11EO 40 34,7 27,9 25,2 22,6 21 19,6 18,5 17,4 16,9 16,4
ZRD 3/K3 1.4581 15EO 10 9,3 8,2 7,9 7,4 7 6,4 6,2 6 5,8 5,7
1.4581 15EO 16 14,9 13,2 12,6 11,9 11,2 10,3 10 9,6 9,3 9,2
1.4581 15EO 25 23,3 20,6 19,7 18,6 17,4 16,1 15,6 15 14,6 14,3
1.4581 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
ZRD G/API594, ZRD G4/API594 EN-JL1040 Class125 16 16 14,4 12,8 11,2 9,6
ZRD 6/API594 EN-JL1040 Class150 20 20 18,5 16,5 14,5 12,3
ZRD 4/API594 CC483K Class125 16 16 15 14 13
CC483K Class150 20 20 18 17 16
ZRD 1/API594 1.0619 3EO Class150 20 20 20 19,5 18,5 16,5 14,4 11,3
1.0619 3EO Class300 50 50 49,5 48,5 46 41 35,9 28,3
ZRD 2/API594 1.4308 11EO Class150 20 20 13 11,6 10,7 10 9,5 8,9 8,7 8,35
1.4308 11EO Class300 50 50 32,5 29 26,9 25,3 23,8 22,6 21,7 16,4
ZRD 3/API594 1.4581 15EO Class150 20 20 16,2 15,3 14,3 13,2 12,8 12,3 11,9 11,8
1.4581 15EO Class300 50 50 40,7 38,2 36 33 32 31 29,9 29,2
* EN1092 Teil2 Tabelle17
Lowest working temperature: ZRD G, ZRD G4, ZRD1, ZRD3, ZRD4, ZRD6 minus 10°C; ZRD2 minus 200°C
8.3 Range of Applications
Industrial plants, heating systems, fluids, gases and vapour (see also fluid groups in
table of article 6), hot water heating systems DIN4751 / DIN4752, heat transmission
plants DIN4754, steam boiler plants TRD110, pressure vessel plants TRB801
No. 45. Potential restrictions by any technical body of legislation are to be
considered. The materials of the valves have to be applicative for the medium.
11
Opening Pressures pö (mbar)
- depending on flow direction -
SR / HSR ZRK / ZRL ZRD
DN « ¯ no « « with spring with spring « with
spring spring
15 20 16 24 4
20 20 16 24 4
25 20 16 24 4
32 20 16 24 4
40 20 15,5 24,5 4,5
50 20 15 25 5 ~0 15 8 23 15 25 10
65 20 14,5 25,5 5,5 ~0 15 8 23 15 25 10
80 20 13,5 26,5 6,5 ~0 15 8 23 15 30 15
100 20 13,5 26,5 6,5 ~0 15 8 23 15 30 15
125 20 - 34 14 ~0 10 8 18 15 35 20
150 20 - 33 13 ~0 10 8 18 15 35 20
200 20 - 32 12 ~0 10 12 22 15 35 20
250 20 - 32 12 ~0 10 12 22 15 35 20
300 20 - 32 12 ~0 10 12 22 15 45 30
350 20 - 32 12 ~0 10 15 25 15 45 30
400 20 - - - ~0 10 16 26 15 45 30
450 20 - - - ~0 10 16 26 15 55 40
500 20 - - - ~0 10 22 32 15 55 40
600 20 - - - ~0 10 24 34 15 75 60
8.4 Installation Instructions
The arrow indicating the flow direction and the flow direction itself need to run in the
same direction.
For the valve to open a minimum dynamic pressure is required. Valves without spring
can only be installed in vertical lines with upward flow.
Installation in
horizontal vertical pipeline
5xDN Eye bolt
DN
DN
Eye bolt
2xDN
Eye bolt
5xDN
5xDN
Pump
Eye bolt indicates

top position of
the valve
12
Wafer type non-return valves are designed for installation between
two pipeline flanges including appropriate flange sealings. The outer
diameter of the valve centres itself by the flange bolts. The fasteners
Attention require a technical applicability in accordance to the service
conditions. They have to comply with the regulations and have to be
tightened with the permissible torque. Screws, nuts or flange sealings
are not covered by the valve manufacturers’ scope of supply.
9 Initial Operation, Shut-down, Maintenance
9.1 Initial Operation
General information
Materials and service conditions have to be compared with the pipeline system data
before pressure test and initial operation in order to check resistance and load.
For new plants or repairs the pipeline system has to be thoroughly rinsed in order to
clean it from potential welding residues or any other damaging solid particles.
Pressure tests of pipeline sections
Since non-return valves are always in a closed position within a filled pipeline section
a testing overpressure value of 1,1 x PS must not be exceeded (PS = NP = max.
permissible working pressure).
Throughout the pressure test process the valve and the flange connections have to
be examined regarding any leaks. Leakages have to be immediately sealed by
retightening all fasteners.
9.2 Shut-down
If the system is out of operation for a lasting period all media which might change its
condition (i. e. polymerisation, crystallisation, solidification) have to be drained off the
piping system. Rinse the system if necessary.
9.3 Maintenance
The valves are maintenance-free. For safety reasons and in order to avoid
unnecessary periods of interruption the operator is advised to examine functionality
and reliability of the valves within reasonable and regular intervals (periods to be
defined by the operator).
Safety instructions in chapter 4 are to be considered.
13
9.4 Elimination of Failures
Failure definition Potential reasons Remedy

High leakage rate · Contaminated seat facings ð Clean the seat facings, regrind
if necessary
· Deformation of disc/cone/ ð Replace disc/cone/plate
plate by hammer blow
· Damaged seat ring ð Replace seat ring
· Disc/cone/plate does not ð Recheck operating data,
close, cone is hanging, high reengineer all parts
activity rate causes a seizing
due to friction
Inappropriate noises Insufficient flow rate, ð Select reduced sizes
turbulent flow, decelerated ð Recheck the distance between
starting of the pump pipe bend and pump (5-7xDN)
ð Use lighter plates or springs
with reduced opening pressure
ð Extend the period of running up
the pump
Leaks of stuffing box (ZRL-HG, Stuffing box is inadequately ð Retighten stuffing box
ZRD) preloaded ð Replace stuffing box packings
if necessary
No flow Valve is installed in the ð Arrow of flow direction has to
wrong way run in the same direction as the
flow itself.
Leaks of flange sealings Connection flanges are not ð Retighten fasteners
wired
10 Spare Parts
For repair work any valve parts must only be replaced by spare parts
from the original supplier. Unauthorised conversion as well as spare
Attention parts production cause an expiry of the declaration of conformity and
may also invalidate any warranty claims.
Any springs or o-rings (relevant for valves equipped with a soft sealing) can be
ordered as spare parts. The full marking of the valve body has to be specified in the
purchase order.
14
Safety valves
Type: SAFE-TCP
Pos.: 4.1.2, 5.1.6, 5.2.6

Telefon: 04204/9165-0 Telefon: 0385/640 14-0
Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Safety valves
SAFE SAFE-P
(Series 900) (Series 920)
SAFE-TC SAFE-TCP/TCS
(Series 940) (Series 960/950)
Contents
1.0 General information on 5.0 Installation................................................................7
operating instructions .............................................2 5.1 Safety note .....................................................................8
2.0 Notes on possible dangers .......................................2 6.0 Notes on dangers during installation, operation
2.1 Significance of symbols ................................................ 2 and maintenance......................................................8
2.2 Safety-related definitions .............................................. 2 7.0 Putting the valve into operation .............................9
2.3 Qualified personnel ....................................................... 2 7.1 Potential hazards ............................................................9
3.0 Handling ...................................................................3 8.0 Care and maintenance.............................................9
3.1 Storage .......................................................................... 3 8.1 Setting instructions .....................................................10
3.2 Transport ....................................................................... 3 8.1.1 Removing the cap ................................................................ 11
3.3 Handling before installation.......................................... 3 8.1.2 Changing the set pressure “without” spring change ............ 11
8.1.3 Changing the set pressure “with” spring change ................. 11
4.0 Specification .............................................................3
9.0 Troubleshooting .....................................................12
4.1 Applications .................................................................. 3
4.2 Technical specification.................................................. 3
10.0 Troubleshooting table ..........................................13
4.3 Technical data ............................................................... 4 11.0 Dismantling the valve ..........................................15
4.4 Diagram......................................................................... 5 12.0 Warranty ..............................................................15
4.5 Parts list......................................................................... 6
4.6 Marking......................................................................... 7
0040000083 1102 englisch

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

Non-compliance with operating instructions is dangerous!
Read the operating instructions before installation, operation, maintenance or
disassembly and adhere to them strictly.
2.2 Safety-related definitions
The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.
DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or
considerable damage to property can occur.
WARNING means that if the relevant information is disregarded, there is a danger of serious injury and
/ or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or
damage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specifically emphasised such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product documentation
and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in
turn can cause serious injury to persons or damage to property.
2.3 Qualified personnel
The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-
up and operation of the product and have the qualifications corresponding to their responsibilities such
as:
Instruction and obligation to comply with all operational, regional and in-company regulations and
requirements;
Training or instruction in accordance with safety technology standards with regard to the upkeep and use
of appropriate safety and work protection equipment;
First aid training, etc.
page 2 0040000083 1102

Safety valves
3.0 Handling
3.1 Storage
- Storage temperature -20˚ to +65˚C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘t
damage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.
3.2 Transport
- Transport temperature -20˚ to +65˚C.
- Protect against external force (impact, vibration etc.).
- Don‘t damage the paintwork.
3.3 Handling before installation
- If flange covers are fitted, remove shortly before installation!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.
4.0 Specification
4.1 Applications
Safety valves are safety devices designed to prevent the pressure in any pressurised system from
exceeding the maximum permissible pressure by more than the permissible tolerance of, usually +10%.
The engineer planning a plant is responsible for selecting the correct valve for a given application.
The special features of the valve concerned must be taken into account.
Oil and grease free
for oxygen application
- Valves for oxygen application (O2) have a fixed plate.
- Valves for Ammonia (NH3) acc. to TRD 451-452 must be free from nonferrous metals
with flanges DIN 2512 form N.
- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.
- Valves for inflammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
- -marking for applications acc. to Pressure Equipment Directive on request.
4.2 Technical specification
Terms as defined in DIN 3320 T1, TRD 421, TRD 721, AD-A2, *ASME Code Section VIII-Devision 1
Direct loaded safety valve
A direct loaded safety valve is a valve, in which the opening force underneath the valve disc is opposed
by a closing force such as a spring or a weight.
*Standard safety valve
A standard safety valve is a valve which, following opening, reaches the degree of lift necessary for the
mass flow to be discharged within a pressure rise of not more than 10%. No further requirements are
made for the opening characteristics.
Full lift safety valve
A full lift safety valve is a valve which, after commencement of lift, opens rapidly within a 5% pressure
rise up to the full lift as limited by the design. The amount of lift up to the rapid opening (proportional
range) shall not be more than 20% of the total lift.
0040000083 1102 page 3

Safety valves
4.3 Technical data
Series 900 : DN 20/32 - DN 150/250, 1“x2“ - 6“x10“
Cast iron grades GG-25, GGG-40.3;
cast steel grade 1.0619+N (GS-C25N), 1.4408, SA 216 WCB
PN 16/16, PN 40/16, ANSI 150/150, ASME 300/150
Approved under:
Figure 901, 902, 911, 912 - VdTÜV Notice 100, AD-A2 and TRD 421.
Application letter D/G and F
- ASME Code Section VIII Division 1 (UV-Stamp)
Figure 903, 904, 990 - VdTÜV Notice 100, -100/4, TRD 721, DIN 4751 T1 and 2.
Application letter D/G/H and D (for figures 904, 990)
Series 920 : DN 20 - DN 100

Cast iron grade GG-25; cast steel grade 1.0619+N (GS-C25N), 1.4408
PN 16, PN 40
Approved under:
Figures 921-924 - VdTÜV Notice 100, AD-A2 and TRD 421.

Series 940 : DN 15 - DN 25
Cast iron grade GGG-40.3; cast steel grade 1.4408
PN 40
Approved under:
Figure 941-943 - VdTÜV Notice 100, AD-A2 and TRD 421.

Figure 945-946 - VdTÜV Notice 100, -100/4, TRD 721, DIN 4751 T1 and 2.
Application letter D/G/H and D
Series 950/960 : DN 15 - DN 25 (G 1/2 - G 1)

GGG-40.3, 1.4571
PN 100
Approved under:
Figure 951-953 - VdTÜV Notice 100, AD-A2.

Figure 961-963 Application letter D/G and F
Accessories: Stainless steel bellow for back-pressure compensation; Elastomer bellow;

Soft sealing disc; Lock bush; Proximity switch; Heating jacket; Test gag;
Rupture disc; Support tongues; Removable lifting aid
page 4 0040000083 1102

Safety valves
4.4 Diagram
Fig. 901 Fig. 941 Fig. 961
fig. 1
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow
Lever Disc series 950 Bellow series 940

Fig. 951/952; 961/962
fig. 2
0040000083 1102 page 5

Safety valves
4.5 Parts list
Pos Description Pos Description
1 Body 31 Ring
2 Seat 32 Hex. nut
2a Screwed seat 33 Lift bolt
3 Stud 34 Screw
4 Spindle guide 35 Lift fork
7 Gasket 36 Lifting lever
8 Hex. nut 37 Spring
9 Lift limitation ring 38 Screw
10 Spindle ring 39 Bolt
11 Bonnet, closed 40 Split pin
12 Disc unit 41 Lever open
13 Lifting aid 42 Bonnet, open
14 Spindle 43 Bellow
15 Gasket 44 Ring
16 Spring type straight pin 45 Ring
17 Adjusting screw 47 Ball
18 Ball 48 Retaining ring
19 Spindle cap 55 Bellow unit
20 Parallel pin 59 Protective rim
21 Lock nut 60 Spacer
22 Hex. head screw 61 Coupling
23 Lead seal 62 Weight
25 Snap ring 63 Guide bush
26 Spring plate 65 Coupling
27 Gasket 66 O-Ring
28 Cap, closed 67 Lift button
29 Cap open 68 Spring type straight pin
page 6 0040000083 1102

Safety valves
4.6 Marking
Safety valve (TÜV) d0 αd CE-marking
Set pressure
Size (inch)
Safety valve (ASME) NB-stamp UV-stamp CE-marking
Capacity
Units: SCFM = air Set pressure
LB/HR = steam
GAL/MIN = water
fig. 3: Type test plate

Serial-No. BA/BQ Mechanic
Year
No.
ARI Set pressure (bar / psig)

disc
Approval
E = EPDM up to +150°C
(e.g. UDT, SZU)
V = Viton up to +180°C
N = Neoprene up to +125°C
fig. 4: Body
Series with thread connections are marked on the body.
5.0 Installation
installation work:
- See appropriate TRD 421, AD-A2, DIN, ASME Code rules for piping and installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before installation.
- Safety valves shall be installed with vertical spindle.
- Safety valves shall be installed with upright spindle, not series 950 when marked, „Installation only
horizontal“, then they must be installed horizontally.
- No static, dynamic or thermal loads shall be transferred to the valve.
- Flange gaskets shall be fitted concentrically and not restrict the flow cross section.
- Dirt and foreign bodies shall not be permitted to enter the safety valve.
- Blow-off lines shall be laid with gradient.
0040000083 1102 page 7

Safety valves
- Water shall be drained from the safety valve and blow-off line via the blow-off line (drainage points
always at the lowest point).
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- All drainage systems shall be laid with gradient to a visible discharge.
- The arrangements shall permit the discharge of condensate without danger at all times
Support
Bellow
Drip pan
Drainage Drainage at lowest point
fig. 5
- The blow-off line shall be sufficiently large to ensure that the internal back-pressure while blowing-off
does not exceed 15% of the set pressure.
(Exception: safety valves with metallic bellow for back-pressure compensation).
- The safety valve shall be equipped with a metallic bellow for back-pressure compensation if the back-
pressure exceeds 15% of the set pressure.
- The ratio pao/po shall be taken into account when dimensioning the system.
- The inspection connection on the bonnet of safety valves with metallic bellow is for checking the state
of the bellow as damage to the bellow leads to failure of the safety valve (in this case the bellow would
have no back-pressure compensating effect and the safety valve would not function as required).
- The state of the bellow is checked by connecting a pressure gauge to the inspection connection so that
the back-pressure can be seen in the event of damage.
- Caution: No piping or screws shall project through the inspection connection into the bonnet!
Danger of jamming !
- Safety valves shall be equipped with support tongues to absorb high reaction forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Any blocking screws shall be removed.
5.1 Safety note
Failure to observe the instructions in point 5 may endanger personnel, the plant and other
objects.
6.0 Notes on dangers during installation, operation and maintenance

DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation and
maintained by trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to the
warnings in these operating instructions. In addition, the general installation and safety rules for piping
and plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.
Injury or damage can be caused by ignoring them.
page 8 0040000083 1102

Safety valves
- Check that the data of the valve are correct for the plant (see Typ test plate).
- Remove protective caps and lever lock before putting the valve into service.
- Clean and flush the plant before it is put into operation as dirty media can cause leaks in safety valves.
(See point 5 “Installation”.)
DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modification, always make
sure that:
- all installation and assembly work has been completed!
- only trained personnel (see point 2.3) are employed to start the plant!
- existing guards have been attached and in good order.
7.1 Potential hazards
- Always make sure that the safety valve cannot freeze or become clogged or blocked
(see point 5 “Installation”.)
- The surface temperature of the casing can become very high during operations with high media
temperatures. Danger of burns!
- If no blow-off line is provided, medium may suddenly emerge from the valve outlet. Danger of
scalding, explosion or injury!
- Loud noises may be generated when blowing off.
- Hot media may emerge from the inspection opening of the spring bonnet.
- with open bonnet hot media may escape.
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due to particles
between the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been damaged.
This can only be rectified at our works or by an authorised contractor.
- The safety valve must be lifted from time to time in line with current regulations to ensure that the
valve works correctly.
(The intervals at which this must be done depends on various factors so that no generally applicable
interval can be specified).
Note: Too frequent lifting for test purposes can increase wear of the sealing surfaces.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be returned to the
original position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- Our setting instructions (point 8.1) must be strictly adhered to when changing the set pressure or
changing the set pressure and the spring.
It is best to have these operations done at our works (Schloss Holte- Stukenbrock).
- The manufacturer accepts guarantee liabilities only if tampering by third parties is prevented.
Caution:
Safety valves acc. to ASME Code Section VIII Division 1 are only allowed to be required, altered and
reset by ARI!
0040000083 1102 page 9

Safety valves
8.1 Setting instructions
SAFE-TCS
SAFE-TCP
SAFE-TC
Bellow
Closed cap
Open cap
fig. 6
page 10 0040000083 1102

Safety valves
8.1.1 Removing the cap
Open caps
- Remove pin (39/40).
- Extract lifting lever (41).
- Remove screw (38).
- Unscrew cap (29).
Closed caps
- Press lifting lever (36) towards bonnet (11) and against stop.
- Unscrew cap (28).
Closed cap series 960/950
- Remove spring type straight pin (68)
- Remove lift button (67) / lifting lever (36)
- Unscrew cap (28)
8.1.2 Changing the set pressure “without” spring change
- Check the spring range.

- Spindle (14) must be held fast by all alterations.
- Loosen lock nut (21).
- Turn adjusting screw (17) clockwise to increase and anticlockwise to reduce the set pressure.
- Secure spring setting by tightening lock nut (21).

- Assemble lifting device.
8.1.3 Changing the set pressure “with” spring change

- Spindle (14) must be held fast by all alterations.
- Extract parallel pin (20) and lift off the spindle cap (19).
- Slacken locknut (21) and relieve spring (37) by turning adjusting screw (17) anticlockwise.
- Unscrew nuts (8) at flange connection and remove bonnet (11/42).

Fig. 940: loosen coupling (61)
Fig. 950/960: loosen bonnet (11)
Note: With higher set pressures, the two nuts (8) on the longer studs (3) must be removed last and
simultaneously!
0040000083 1102 page 11

Safety valves
- Remove top spring-plate (26) and spring (37).
- Extract spindle (14) with disc (12/12a), guide plate (4/4a) and bottom spring-plate (26).
- Clean seat (2) and disc (12/12a).
- Insert spindle (14) with disc (12/12a), guide plate (4/4a), spring-plate (26) and different spring (37).
- Fit bonnet (11/42) and reset the set pressure; make sure spring setting range is appropriate.
- Secure spring setting by means of lock nut (21).
- Assemble lifting device.
- If necessary, replace both spring plates (26) and use longer studs (3) when fitting a spring for a higher
set pressure.
- Further information obtainable from the manufacturer.
Only for the 900 series.

When changing the set pressure and fitting a new spring, note that safety valves with set pressures
between 0.2 and 1.5 bar have a greater lift.
Therefore:
Set pressure in the range Spring change only in

the range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
Caution:
Safety valves acc. to ASME Code Section VIII Division 1 are not allowed to be delivered with a lift
limitation!
Only for the 950 series

Caution:
Safety valves for horizontal application, must also to be set in a horizontal position.
9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described in
these instructions.
Compare the DN, opening pressure, blowing-off power, back pressure, operating pressure and
temperature with the information given in the plans of the piping system. Check also that the service
conditions correspond to VDTÜV, AD, TRD, ASME Code and the data given on the Type test 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 12 0040000083 1102

Safety valves
Safety valve does not respond, Flange covers not removed. Remove flange covers.
no flow Relieve pressure first!
Observe points 7.0 and 11.0!
Test gag still in place. Remove test gag.
Spring blocked. Remove pipe or screw projecting into bonnet
through inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety valve.
Relieve pressure first!
Stainless steel bellow defective, Replace the safety valve.
no back-pressure compensation. Relieve pressure first!
Back-pressure not taken into account. Reset (point 8.1) or, if necessary, replace the
safety valve.
The use of a stainless steel bellow to
compensate for back-pressure should be
considered.
Medium viscous or sticky Use bellow / heating jacket. Insert rupture
disc upstream if necessary.
The valves and piping must be protected Heating !
against freezing and solidifying media.
Stem cannot be lifted. Pressure less than 85% of set pressure. It must be possible to lift the spindle at over
85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of set Working pressure must be less than 90% of
pressure. the set pressure.
At low pressures: lever not in neutral position Press lever into neutral position (towards
with closed cap. bonnet).
Safety valve flattering. See separate point “Flattering”.
Medium contaminated; foreign body between Raise spindle briefly or, if necessary, replace
seat and disc. safety valve.
Use of a soft sealing disc should be
considered.
Flange broken. Damage during transport. Replace safety valve.
Flange bolts not evenly tightened. Replace safety valve.
Pressure surges. Safety valve not installed at highest point. Install safety valve at highest point.
Valve drainage inadequate or not fitted. Install drainage system a required by
regulations.
0040000083 1102 page 13

Safety valves
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screw
above cap, Figure 990).
Spring corroded by medium and broken. Replace safety valve.
In the case of vapour, select open cap or
bonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. liquids) Replace safety valve.
emerging from valve. Relieve pressure first!
Select design with closed bonnet and cap.
Install a guard if necessary.
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or radius
in connection socket. Select larger line if
necessary.
Poor welding (root pass), gaskets at inlet and Change conditions.
outlet flanges too small or not concentric. Relieve pressure first!
Safety valve capacity too high. Install smaller safety valve.
Burner capacity too low. Install smaller safety valve.
Blow-off line too long or diameter too small. Use larger diameter or back-pressure
compensation by stainless steel bellow.
Inlet and/or outlet socket too small. Install with dimensions larger than DN of
inlet and outlet lines.
Back-pressure higher than 15%. Install stainless steel bellow for pressure
compensation.
Capacity too low. Safety valves not applied unsuitable for plant Select and install suitable safety valves.
conditions. Relieve pressure first!
Safety valve not applied in line with current Adjust conditions.
DIN, AD, TRD, etc. rules. Relieve pressure first!
Caution: - Read point 11.0 prior to dismantling and repair work!

- Read point 7.0 before restarting the plant!
Caution:
Safety valves acc. to ASME Code Section VIII Division 1 are only allowed to be required, altered and
reset by ARI!!
page 14 0040000083 1102

Safety valves
11.0 Dismantling the valve
The following points must be observed beside the general principals rules governing the assembly work:
- pressureless pipe system.
- medium must be cool.
- plant must be drained.
- purge piping systems in case of caustic, inflammable, aggressive or toxic media.
- have assembly work performed only by qualified personnel (see point 2.3).
12.0 Warranty
The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert
Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale
itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed
application.
No warranty claims can be made for any damage caused as the result of incorrect handling or disregard
of operating and installation instructions, accident prevention regulations, EN, DIN, VDE, ASME Code
standards and other applicable codes of practice.
Damage arising from operation under service conditions differing from those specified in the VdTÜV
sheet, AD, TRD, ASME Code (cf. point 4.3) or other agreements is also excluded from the guarantee.
Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is
excluded.
The warranty shall not cover maintenance work, installation of external parts, design modifications or
natural wear.
Any damage incurred during transport should not be reported to us but rather to the competent cargo-
handling depot, the railway company or carrier company immediately or else claims for replacements
from these companies will be invalidated.
0040000083 1102 page 15

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kupke + wolf gmbh kupke + wolf gmbh

Hägerstr. 22 Werkstraße 226

Spare parts and other components

+49 (385) 64014 - 62

+49 (385) 64014 - 14

D - 27321 Thedinghausen D - 19061 Schwerin

Spare parts and other components

We work together with well-known world-wide courier services

If requested we are able to store spares for our customers

Beside the production of fuel oil modules Kupke + Wolf also

- Oily-water separators (HEISHIN-Pump Works)

- Viscosity control systems

- Fuel oil blending units

- bunker control systems

- flowmeters for most fluids

- filtration units (e.g. automatic filters)

- gear pumps, centrifugal pumps, screw pumps

- shut-off valves, ball valves, quick-closing valves

- fittings (e.g. thermometers, manometers)

- steam-, thermal oil- and electrical-operated heaters

We are proud of our wide range of supply which allows us

D - 27321 Thedinghausen D - 19061 Schwerin

design office: ………………………………………………………………………………...

contact person: ……………………………………………………………………………...

phone no. *: …………………………………………………………………………………

fax no.: …………………………………………………………………………………

hull no.: …………………………………………………………………………………

serial no.: …………………………………………………………………………………

your inquiry: …………………………………………………………………………………

* = Please necessarily fill in this field.

D - 27321 Thedinghausen D - 19061 Schwerin

B. .............................................General danger and safety information

C./D. .................................................................Start-up/ Commissioning

1. ....................................................................................Pumps with drive

3. ............................................................................................... Flow meter

D-27321 Thedinghausen D-19061 Schwerin/Wüstmark

6. ................................................................Viscosity measuring system

8. ..................................................................... Instruments and sensors

9. ........................................................................Heating medium control

10. ..................................................................................................... Valves

D-27321 Thedinghausen D-19061 Schwerin/Wüstmark

D-27321 Thedinghausen D-19061 Schwerin/Wüstmark

Customer: MPC Münchmeyer Petersen Marine GmbH

Module type: KAH-8-C60-2D

BASIC TECHNICAL DATA:

MAIN DIESEL ENGINE:

heating medium (heater): steam, 0.7 MPa (165 °C)

assumed module inlet temp.: 80 °C

D-27321 Thedinghausen Werkstraße 226 Deutsche Bank Bremen Geschäftsführer

03/07/2006 ts18501_e-mail 2/9

D-27321 Thedinghausen Werkstraße 226 Deutsche Bank Bremen Geschäftsführer

fuel oil outlet of the module: DN 50

weight: approx. 3,000 kg

BASIC MODULE DESIGN DATA:

03/07/2006 ts18501_e-mail 3/9

D-27321 Thedinghausen Werkstraße 226 Deutsche Bank Bremen Geschäftsführer

PRESSURIZED FUEL OIL SUPPLY AND BOOSTER MODULE

1. CHANGE OVER VALVE, POS. 10.1