INSTRUCTION MANUAL 1(141)

Document id: IM8569

1 STORAGE, HANDLING AND INSTALLATION ..............................................................5

1.1 Storage...................................................................................................................5
1.2 Handling .................................................................................................................5
1.3 Installation ..............................................................................................................5
2 SAFETY INSTRUCTIONS .............................................................................................7
3 WARNINGS AND INSTRUCTIONS ...............................................................................7
4 START-UP .....................................................................................................................8
5 SHUTDOWN ................................................................................................................10
6 TROUBLE SHOOTING ................................................................................................11
7 MAIN SWITCH .............................................................................................................12
8 ELECTRONIC TIMER, CT-S RANGE, TYPE 1SVR6300 ............................................13
8.1 Operating controls ................................................................................................13
8.2 Electrical diagram .................................................................................................14
8.3 Function diagrams ................................................................................................15
8.4 Factory settings by Auramarine Ltd. .....................................................................17
9 COUNTER, TYPE H7E ................................................................................................18
10 ALARM PANEL ........................................................................................................20
10.1 Alarm panel for units with LRS classification ........................................................21
11 VISCOSITY AND TEMPERATURE CONTROLLERS E5EK ...................................22
11.1 Operation .............................................................................................................25
11.2 Access to parameters...........................................................................................26
11.3 Parameter settings of the viscosity controller A16A1 ...........................................27
11.4 Parameter settings of the temperature controller A16A2......................................30
12 PRESSURE SWITCH MBC 5000, 5100 ..................................................................33
13 LEVEL LIMIT SWITCH LIQUIPHANT T FTL20 .......................................................34
13.1 Instructions ...........................................................................................................34
14 FLOW METER TYPE B-SERIES .............................................................................36
14.1 Start-up procedures..............................................................................................36
14.2 Initial start-up of a flow meter system with bypass: ..............................................36
14.3 Initial start-up of a flow meter system without bypass ..........................................37
14.4 Maintenance .........................................................................................................38
14.4.1 General .........................................................................................................38
14.4.2 Accuracy check .............................................................................................38
14.4.3 Check of the totaliser ....................................................................................38
14.4.4 To remove flow meter from piping system ....................................................39
14.4.5 To remove counter from flowmeter ...............................................................40
14.4.6 To remove magnet cap and magnet .............................................................40
14.4.7 To remove front cover ...................................................................................41
14.4.8 To remove rotor/vanes assembly ..................................................................42
14.4.9 To remove back cover ...................................................................................43
14.4.10 To inspect inside of meter body .................................................................43
14.4.11 To inspect rotor and vanes ........................................................................44
14.4.12 To inspect bearings and rotor shaft ...........................................................45
14.4.13 To replace bearings ...................................................................................45
14.4.14 To re-assemble a flowmeter ......................................................................45
14.4.15 To install back cover ..................................................................................46
14.4.16 To install front cover to meter body ...........................................................49
14.4.17 To install inner magnet ..............................................................................49
14.4.18 To install magnet cap ................................................................................50
14.4.19 To install pulse transmitter box or counter .................................................50

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14.4.20 Final performance check ...........................................................................50

14.5 Trouble shooting...................................................................................................51
14.6 Optional pulse transmitter ....................................................................................52
14.7 Optional pulse discriminator .................................................................................54
15 VISCOMASTER TYPE 7829 ...................................................................................55
15.1 Viscomaster measurements .................................................................................55
15.2 During a normal run..............................................................................................55
15.3 Removal and refitting procedure ..........................................................................56
15.4 Surge protection ...................................................................................................57
15.5 ADView ................................................................................................................57
15.6 Maintenance .........................................................................................................58
15.6.1 General inspection and maintenance ............................................................59
15.7 Calibration ............................................................................................................60
15.7.1 Ambient air calibration check ........................................................................61
15.7.2 On-line calibration adjustment .......................................................................61
15.7.3 Calibration adjustment - stable liquids: ..........................................................62
15.7.4 Calibration adjustment - unstable or high vapour pressure liquids: ...............62
15.8 Trouble shooting...................................................................................................63
16 HEAT EXCHANGER, TYPE S14 .............................................................................64
16.1 Starting up and running instruction .......................................................................64
16.2 Opening and assembling ......................................................................................65
16.3 Cleaning ...............................................................................................................65
16.3.1 Manual Cleaning ...........................................................................................66
16.3.2 CIP Cleaning .................................................................................................66
16.3.3 Cleaning Materials ........................................................................................66
16.4 Fault location ........................................................................................................68
16.4.1 Reduced Capacity .........................................................................................68
16.4.2 External Leakage ..........................................................................................68
16.4.3 Inside Leakage ..............................................................................................68
16.5 Reassembly .........................................................................................................69
16.6 Spare parts ...........................................................................................................69
17 HEAT EXCHANGER TYPE MX ...............................................................................70
17.1 General Description..............................................................................................70
17.2 Operation .............................................................................................................70
17.2.1 Commissioning..............................................................................................70
17.2.2 Initial start-up.................................................................................................70
17.2.3 Output ...........................................................................................................70
17.2.4 Conservation during shut down periods ........................................................71
17.3 Maintenance and cleaning ...................................................................................71
17.3.1 Regular cleaning periods...............................................................................71
17.3.2 Cleaning of tubes ..........................................................................................71
17.3.3 Heavy contamination .....................................................................................72
17.3.4 Checking the safety valves ...........................................................................72
17.3.5 Dismantling and reassembling of the tube section ........................................72
17.4 Spare parts ...........................................................................................................73
18 SCREW PUMP, TYPE ACE3 WITH MAGNETIC COUPLING .................................74
18.1 Start-up ................................................................................................................76
18.1.1 Before starting ...............................................................................................76
18.1.1.1 Direction of rotation ............................................................................... 76
18.1.2 Starting ..........................................................................................................77
18.1.2.1 Setting the pressure relief valve ............................................................ 77

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18.2 Maintenance .........................................................................................................78

18.2.1 Inspection of rotors........................................................................................79
18.2.2 Magnetic coupling .........................................................................................80
18.2.3 Dismantling ...................................................................................................81
18.2.4 Reassembly ..................................................................................................84
18.3 Trouble shooting...................................................................................................87
18.4 Components .........................................................................................................90
18.4.1 Spare parts ...................................................................................................91
19 AC ELECTRIC INDUCTION MOTORS....................................................................92
19.1 Maintenance .........................................................................................................92
19.1.1 Periodic maintenance ....................................................................................92
19.1.2 Wound rotor ..................................................................................................93
19.1.3 Hazardous area motors .................................................................................93
19.2 Replacing non-drive end bearing..........................................................................93
19.2.1 Bearing removal ............................................................................................93
19.2.2 Bearing replacement .....................................................................................94
19.3 Spare parts ...........................................................................................................95
20 LIMIT SWITCH TYPE PCR ......................................................................................98
20.1 Wiring Diagram.....................................................................................................99
21 BALL VALVES, TYPES N2, N8 AND N9 ...............................................................100
21.1 Operation ...........................................................................................................100
21.1.1 Manual operation ........................................................................................100
21.1.2 Automated operation ...................................................................................100
21.2 Maintenance .......................................................................................................100
21.2.1 Steam leakage ............................................................................................101
21.2.2 Body seals leakage .....................................................................................101
21.2.3 In line or seats leakage ...............................................................................101
21.3 Valve disassembly to inspect and/or replace body seals, seats, packing and ball102
21.4 Inspection and replacement ...............................................................................102
21.5 Re-assembly ......................................................................................................102
21.5.1 Steam re-assembly .....................................................................................102
21.5.2 Ball, seats and seals re-assembly, types N8 and N9 ..................................103
21.5.3 Ball, seats and seals re-assembly, type N2 ................................................103
21.6 Testing ...............................................................................................................103
21.7 Automated ball valves ........................................................................................103
21.8 Tightness values for handle nut 2A-2B and body bolts 16, types N8 and N9 .....104
21.9 Tightness values for handle nut 2A-2B and body bolts 16, type N2 ...................104
21.10 Storage ...........................................................................................................104
21.11 Spare parts .....................................................................................................105
22 PRESSURE LIMITING VALVE SPVF ....................................................................106
22.1 Description of operation .....................................................................................107
22.2 Constructions and spares ...................................................................................107
22.3 Adjustment .........................................................................................................108
22.4 Venting ...............................................................................................................108
23 VALVE, SERIES 776000 .......................................................................................109
24 SWITCHBOX, SERIES W AUTOMAX ...................................................................110
24.1 Adjusting limit switches ......................................................................................110
25 VALVE, TYPES KE 71 AND KE 73........................................................................112
26 ELECTRIC LINEAR ACTUATORS, SERIES EL5600 ............................................113
26.1 Operation ...........................................................................................................114
26.1.1 Manual operation ........................................................................................114

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26.2 Maintenance .......................................................................................................115

26.3 Spare parts .........................................................................................................115
27 STOP BELLOW VALVE, TYPE 234 ......................................................................116
28 AUTO FILTER 6.62................................................................................................117
28.1 General ..............................................................................................................117
28.2 Commissioning ...................................................................................................119
28.3 Control of automatic filter, type 6.62 ...................................................................120
28.3.1 Chamber fill up time change........................................................................121
28.3.2 Flush period change ....................................................................................122
28.3.3 Flush time change .......................................................................................122
28.3.4 Parameter settings ......................................................................................122
28.3.5 Set clock is selected to set time and date. ..................................................123
28.4 Maintenance .......................................................................................................124
28.4.1 Servicing Tools............................................................................................125
28.4.2 Candle Element Cleaning Agent "BOLL CLEAN 2000" ...............................126
28.4.2.1 Mesh contaminated with heavy oil ...................................................... 126
28.4.2.2 Instruction for use ............................................................................... 126
28.4.3 Manual Cleaning of the Candle Elements ...................................................127
28.4.4 Maintenance instructions (bypass filter) ......................................................128
28.5 Spare parts .........................................................................................................132
28.5.1 Type 6.62.1 .................................................................................................132
28.5.2 Type 6.62 ....................................................................................................135
29 PRESSURE VESSELS ..........................................................................................140
30 HOW TO ORDER SPARE PARTS ........................................................................141

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1 STORAGE, HANDLING AND INSTALLATION

1.1 Storage

The unit is to be protected from rain, snow and dirt. In order to avoid
condensation, it is recommended to avoid temperature variation.

Storage temperature -10 to +60ºC

Ambient humidity max. 85%

1.2 Handling

packed unit unpacked unit

Unit is handled from lift hangers or with forklift truck. Used lifting
device is to have adequate lifting capacity and break resistance,
and it is prohibited to be under lifted load.

1.3 Installation

Package material is wood and plastic. Package materials are to be

disposed or recycled according to local law.

Before final installation and fastening of the unit, the following is to be

taken into account:

Visual inspection is recommended in order to see possible

damages caused by transport or moving to the installation
place.

Needed service space can be seen in the general

arrangement drawing.

Installation place is to be as vibration free as possible.

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Installation place must have adequate ventilation in order to

prevent explosion danger.

The unit must be fastened with bolts or by welding, see

general arrangement drawing. Additional bracing of booster
unit must be done if vibration is detected.

Plugs of pipe connections are to be removed before

installing pipes to fuel oil unit.

It is recommended that all HFO pipelines connected to fuel

oil units are insulated and trace heated.

Pipeline connections can be seen in the general

arrangement drawing.

Electrical connections can be seen in the interconnection

pages of the electric drawings.

Protective bonding to be executed according to the

standards of the installation place.

Before start-up, activate the gas generator of the

SealGuard, if installed.

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2 SAFETY INSTRUCTIONS

1. Read the instruction manual for the unit.

2. Wear protective clothing, ear defenders and eye protection. Danger
of burning lesion. Beware of hot surfaces, hot oil and noise.
3. Switch voltage off before maintenance occurs.
4. Electrical work must be carried out according to the standards by
authorised persons.
5. Close shut off valves from both sides and depressurise the
equipment and pipes before any maintenance action. To prevent
danger of hot liquid/steam spray.
6. Use crane to lift heavy parts during maintenance and ensure that
parts removed come off in a controlled manner.
7. After maintenance, ensure that all parts are assembled correctly.
8. Ensure that the safety instructions for all cleaners, oils and paints are
available.
9. Keep the environment of the unit clean. "Slippery floors may cause
injury."
10. Smoking is not allowed in the immediate surroundings of fuel oil units.
11. Unwanted equipment and chemicals should be disposed of in a safe
manner and according to local laws and regulations.

3 WARNINGS AND INSTRUCTIONS

1. Pumps start automatically after power failure.

2. Run only one pump and heater simultaneously. Switch the other
pump to
stand-by.
3. Ensure fuel oil flow through intended heater.
4. Turn trace heating on if unit is stopped during HFO running.
5. Keep the feeder pressure setting at least at 3 bar.
6. Do not heat LFO/MDO above 50°C.
7. Do not adjust feeder/booster pressure from pumps.
8. Do not run pumps dry.
9. Electric heaters and steam/thermal oil control valve are interlocked
with booster pumps viscometer and HFO/LFO, MDO three way valve.
10. It is recommended that all HFO pipelines connected to fuel oil units
are insulated and trace heated.
11. In case of no instrument air by pass filter is to be used.
12. Make sure that the operating pressure of the pressure vessel does
not exceed the design pressure, that the temperature of the pressure
vessel’s contents does not exceed the maximum allowed operating
temperature and that- the connections do not leak.

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4 START-UP

Before start-up, activate the gas generator of the SealGuard, if

installed.

1. Switch main switches and all control switches of the unit to off
position.
2. Switch instrument air on to fuel oil units.
3. Ensure LFO/MDO flow to feeder/booster unit. Suction pressure
gauge of the unit should indicate pressure (>0 bar). Open the
equipment valves of feeder/booster unit and close by-pass valves.
4. Check that valves of the engine(s) are in right position.
5. Ensure that fuel oil from engine(s) flows to booster unit’s mixing tank.
6. Ensure that all miniature circuit breakers, motor circuit breakers and
moulded case circuit breakers are switched on in local control
panel(s) of the fuel oil unit(s).
7. Switch main switch to on position.
8. After resetting the alarm panel, the following alarms should be on.
Low outlet pressure (if installed), low level in mixing tank, low
viscosity (if not blocked with signal from HFO/LFO, MDO valve).
9. Start feeder pump and check rotation direction.
10. To fill fuel oil unit and pipelines to and from engine(s) with LFO/MDO
will take from two to ten minutes.
11. Low level in mixing tank alarm will go off after tank is filled. In case of
manual deaeration open the deaeration valve until the low level alarm
goes off.
12. Pressure in fuel oil unit and engine(s) should rise to range from three
to five bar. If not, check positions of valves.
13. Change running feeder pump. Check rotation direction. Use always
one pump as running and one pump as stand-by. Change running
pump periodically in order to run pumps equally.
14. Check that steam/thermal oil valves are closed and electric heaters
are off.
15. Start booster pump. Check rotation direction. Pressure in pipelines
after booster pumps should rise to range from six to nine bar (setting
in engine’s equipment). Low outlet pressure alarm goes out (if
installed).
16. Change running booster pump. Check rotation direction. Use always
one pump as running and one pump as stand-by. Change running
pump periodically in order to run pumps equally.
17. Start viscometer. Viscosity of LFO/MDO is in range from three to
eight mPas.
18. Low viscosity alarm is on (if not blocked with signal from HFO/LFO,
MDO valve).
19. Start auto filter.
20. Start engine.
21. Change fuel oil from LFO/MDO to HFO.
22. Ensure that needed trace heating is on.

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23. If there is HFO/LFO, MDO valve in feeder/booster unit turn it to HFO

position.
24. Open steam/thermal oil valves or switch electric heater on by control
switch at local control panel.
25. Ensure the operation of viscosity/temperature controller if they are not
installed to local control panel by Auramarine Ltd.

a) Choose controller by control switch at local control panel.

b) Set setpoint above process value. Control valve should
open or stages of electric heater should increase power.
c) Set setpoint below process value. Control valve should
close or stages of electric heater should decrease power.
d) In case of malfunction, check wiring.
e) Set setpoint to normal and viscosity control on.

26. Low viscosity alarm goes out after engine has consumed all
LFO/MDO from circulation.
27. After engine has run from 1,5 to 2 hours with HFO, check all pipe
connections, and in case of leakage, tighten the pipe connection.

Attention

Fuel oil viscosity can be regulated by viscosity or by temperature.

Recommended way is to use viscosity control, because it

keeps the injection viscosity constant regardless of the fuel
oil quality by regulating temperature.

As back-up fuel oil viscosity can be controlled by temperature.

Selection by above mentioned controls is done by control switch at local

control panel and valves of heaters and valves of steam/thermal oil lines.

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5 SHUTDOWN

1. Circulate the fuel oil through heater at least ten minutes after turning
heating off in order to cool the heater down.
2. Turn the trace heating on if there is HFO in pipe system of the fuel oil
unit.

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6 TROUBLE SHOOTING

Problem Check points / actions

Open suction valves if they are closed.
Stand-by pump Suction pressure should be above -0,5 bar, if below clean the
starts. suction strainers.
Setpoint of pressure control valve should be 4-5 bar.
The by-pass valve of the pressure control valve should be closed.
Check rotation direction of pumps.
Check pressure control valve setting at engine(s) equipment.
Ensure that fuel oil from engine(s) flows to booster unit’s mixing
tank.
The shut of valve of the pressure switch should be open.
The deaerating valves of the heaters and mixing tank should be
closed.
Check the operation of the auto filter and by-pass filter of the auto
filter.
Check the operation of the pressure switch and the alarm panel
Check the settings and cleanness of the internal over flow valves
of the pumps.
Check that the delay of the stand-by pump start is sufficient.
Check positions of valves
Pressure too high at Run only one feeder and one booster pump simultaneously.
pump outlet. Setpoint of pressure control valve at engine(s) equipment may be
too high.
Clean the heaters.
Check the operation of the auto filter and by-pass filter of the auto
filter.
Check the positions of the steam/thermal oil valves.
Heating is not Moulded case circuit breakers of the electric heaters should be
working. on.
Safety thermostats of the electric heaters may be tripped.
Control switch of the electric heater should be on.
Viscometer is not running.
The by-pass valve of the heater should be closed.
HFO/MDO, LFO valve should be in HFO position.
Check positions of control switches at local control panel.
Viscometer is not Viscometer should be on and viscosity control should be selected.
working. Check wiring of the controller and viscosity measuring loop.
By-pass valve of the viscometer should be closed.
Check the selector switch of density at viscometer.
Low level in mixing Feeder pump is not running.
tank. Fuel from engine does not flow to the mixing tank of booster unit.
Check the cleanness of the flowmeter filter and rotor.
Flow meter is not The valves of the flow meter are closed.
working. The by-pass valve of the flow meter is dirty.
Check wiring and settings if there are out going signals.
Working pressure is above the setpoints of the safety valves.
Safety valve is open. Setpoint at mixing tank is 10 bar and at heaters 15 bar.
Valves after heaters should be open.
Safety valve is damaged.

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7 MAIN SWITCH

Door of the control panel can be opened with main switch on by pressing
with a pin to hole shown below.

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8 ELECTRONIC TIMER, CT-S RANGE, TYPE 1SVR6300

8.1 Operating controls

1. Adjustment of the time range by selecting the

max. value:

Range Max. value

0.15 - 3 s >> 3 s yellow
1.5 - 30 s >> 30 s dial
15 - 300 s >> 300 s
1.5 - 30 min >> 30 min
15 - 300 min >> 300 min
1.5 - 30 h >> 30 h
15 - 300 h >> 300 h
0.05 - 1 s >> 1 s white
0.5 - 10 s >> 10 s dial
5 - 100 s >> 100 s
0.5 - 10 min >> 10 min

2. Direct reading scale to set the time value

within the chosen range

3. Function /
Selection of the function on CT-MFS
and CT-MBS
Functions: see III

4. Setting of the 2nd c/o contact as an

instantaneous contact
Position Inst. “I”: Instantaneous contact

5. Status display with LEDs:

U/T: green LED Status indication of

control supply
voltage and timing
Control supply
voltage applied
Time delay is running

R: yellow LED - Status indication of output relay

energized

R1/R2: yellow LED - Status indication of output relay 1/2

energized

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8.2 Electrical diagram

For the rated control supply

voltage and the circuit
diagram, see label at the
side of the unit

A1-A2 Control supply voltage Us

Y1-Z2 Control input to start timing
X1-Z2 Control input to pause timing /
accumulative function
(see diagram under V)
Z1-Z2 Remote potentiometer
connection for the fine
adjustment of the time delay.
When an external
potentiometer is
connected, the internal, front-
face potentiometer is disabled.
15-16/18 1st c/o contact
25-26/28 2nd c/o contact
(21)-(22)/(24) 2nd c/o contact, set as
instantaneous contact

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8.3 Function diagrams

CT-MBS and CT-MFS

1. ON-delay
t adjusted time delay

2. Impulse-ON
t adjusted pulse time

3. Flasher with reset, starting

with ON
t adjusted flashing time

4. Flasher with reset, starting

with OFF
t adjusted flashing time

5. OFF-delay with auxiliary

voltage
t adjusted time delay

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6. Impulse-OFF with auxiliary

voltage
t adjusted pulse time

7. Star-delta change-over with

impulse
function
t1 adjusted starting time
t2 fixed transition time of 50
ms

8. ON-delay and OFF-delay,

symmetrical
t1 adjusted ON-delay
t2 adjusted OFF-delay

9. Pulse former
t adjusted pulse time

10. ON/OFF-Function
ON-Function - time sector ≠
300 h
OFF-Function -time sector =
300 h

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CT-AHS
5. OFF-delay with auxiliary
voltage
t adjusted time delay
CT-ARS
11. OFF-delay without auxiliary
voltage
t adjusted time delay

8.4 Factory settings by Auramarine Ltd.

Duty Mode Setting

delay of stand-by start (delay on release) 5 3 seconds

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9 COUNTER, TYPE H7E

The product has a built-in lithium battery. Do not short-circuit the +

and - terminals, charge, disassemble, deform, or expose the
battery to fire. The battery may explode (break), catch fire, or
cause liquid leakage.

Do not use any battery other than the specified one (Y92S-36).
Using another battery may cause liquid leakage or breakage,
resulting in malfunction or injury.

If a voltage other than the rated one is applied, internal elements

may be damaged.

Do not use the Counter in locations subject to direct sunlight,

subject to corrosive gases or subject to dust.

Nomenclature

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Battery replacement

Remove the wiring when replacing the battery. Do not come contact with
any item to which high voltage is being applied. Doing so may result in
electric shock.
Before changing the Battery, the person should ensure that they are not
carrying any static electric charge.

Procedure for replacing the Battery (refer to the diagrams below):

1. Using the tool, pry open the lift-tab on the case. (1)
2. Pull the body out of its outer case. (2)
3. Lift the Battery up by the edge and remove it. (3)

When removing the Battery, do not come in contact with the display
area or any internal parts.

4. Wipe the back of the new battery before inserting it.

5. Ensure that the + and – terminals are correctly oriented.
6. After replacing the Battery, re-insert the body into its
case. (4)

Check that the case is securely held in by the lift-tab

7. Press the Reset Key before use (not necessary for

H7ER-N, -NV, -NV1). (5)

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10 ALARM PANEL

LLC-10 is a compact alarm display unit in the "DIN"-series. It is designed

for exacting applications. The unit is programmable for use with either
normally open or closed sensor contacts, and with adjustable time delay
for each alarm channels. The alarm channels can be connected to either
of the two output groups (A and B alarms). At the panel, the sensors
indicator flashes when the pre-set time delay has elapsed. At the same
time the output group to which it is connected, is activated. The signal is
acknowledged by pressing the red RESET button. This releases the
output contact and the flashing light becomes steady. When the fault has
been corrected and the sensor contact has returned to its normal state,
the indicator lamp goes out. If the fault self-corrects and the sensor
contact returns before acknowledgement, the fault remains in the unit
memory, the light flashes and the output contact remains activated, until
the accept button is pressed. LLC-10 is equipped with a channel
memory. The unit is always ready to receive new alarm signals,
independent of system status. The panel can be provided with legends
for each alarm channel or with a common 10 points legend.

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10.1 Alarm panel for units with LRS classification

LLC-10 LRS is a compact alarm display unit in the "DIN"-series. It is

designed for exacting applications. The unit is programmable for use with
either normally open or closed sensor contacts, with adjustable time
delay. The alarm system has two output groups (A and B alarms). All
channels shall be connected for A-alarm. At the panel, the sensors
indicator flashes when the pre-set time delay has elapsed. At the same
time the both output group is activated (the B group is delayed 5 sec. in
relation to the A group). If a new sensor will be activated the B group
relay will do a quick status change. The signal is acknowledged by
pressing the red RESET button. This releases the output contact and the
flashing light becomes steady. When the fault has been corrected and
the sensor contact has returned to its normal state, the indicator lamp
goes out. If the fault self-corrects and the sensor contact returns before
acknowledgement, the fault remains in the unit memory, the light flashes
and the output contact remains activated, until the accept button is
pressed. LLC-10 is equipped with a channel memory. The unit is always
ready to receive new alarm signals, independent of system status. The
panel can be provided with legends for each alarm channel or with a
common 10 points legend.

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11 VISCOSITY AND TEMPERATURE CONTROLLERS E5EK

Precautions Use the following type of solderless terminals for

General Precautions M3.5 screws-
Operating environment
Keep within the rated ambient operating
temperature, ambient operating humidity, and
storage temperature ranges.
Use the Unit according to the vibration resistance,
shock resistance and enclosure ratings. Operation
Do not use the Unit is places with. corrosive gas or The alarm outputs of the model with an alarm
excessive dust. function may not turn ON properly when the model
Do not use the Unit nearby machines. generating malfunctions. The use of alarm equipment with the
high frequency noise. modle is recommended.
Correct use The parameters and internal switch are set before
Mounting shipping so that the Unit will function normally.
The dimensions of the Digital Controller conform Change the settings of the parameters and
to DIN 43700 internal switch according to the application if
Recommend panel thickness is 1 to 8 mm. necessary.
Mount the Unit horizontally. Several seconds are required until relay is turned
Connection ON after power has been supplied to the Digital
To reduce inductive noise influence, the lead wires Controller. Therefore, take this time delay into
connecting the input type of the Digital Controller consideration when designing sequenced circuits
must be separated from the power lines and load which incorporate a Digital Controller.
lines Do not use excessive force when drawing out the
Use the specified compensating conductors for internal mechanism from housing. Protect against
thermocouples. static discharge when changing the settings of the
Use lead wires having small resistance for internal switch. Changing the settings on a
platinum resistance thermometers grounded conductive mat is recommended.
Connection Example When connecting the Control Output Unit to the
Wire the terminals of the Unit using solderless Temperature Controller or Digital Controller, make
terminals. sure that the Control Output Unit is a suitable type.
The tightening of the torque applied to the terminal The use of an improper type of Control Output Unit
screws of the Unit must be approximately 0.78 may cause the system to malfunction.
N*m or 8 kgf*cm The heater burnout alarm will not be available if
the Linear output Unit is used.

Note:
1.Recommended panel thickness is 1 to 8 mm.
2.Maintain the specified vertical and horizontal mounting space between
each unit. Units must not be closely mounted vertically and horizontally.

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1. Insert the E5AK Controller into 3. Tighten the mounting bracket

the panel’s mounting hole at the screws on the upper and lower parts
position shown in the figure of the E5AK in small increments
alternately and equally until the ratchet
start to slide
2. Fit the mounting
bracket(accessory) into the fixing
slots on the top and bottom of the
rear case

E53-COV0809, E53-COV08 Terminal Cover (Sold Separately)

Fasten the terminals covers as follows by using the snap pins. Snap pins
are provided with the terminal covers

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No. 1 display Displays the process value or parameter symbols

No. 2 display Displays the setpoint, manipulated variable or parameter settings
Out 1 Lits when the controller increases heat
Out 2 Lits when the controller decreases heat
Sub 1 Lits when the low viscosity alarm is on
Sub 2 Lits when the high viscosity alarm is on
Manu Lits when the manual operation mode is on
Stop Lits when operation has stopped
RMT Lits during remote operation (not in use by Auramarine)
RSP Lits during remote SP operation (not in use by Auramarine)
AT Flashes during auto tuning

A/M key Each press of this key switches between the auto and manual operations.

Display key The functions of this key change according to how long it is pressed. If the key is pressed for less than one
second, the parameters are switched. If the key is pressed for one second or more, the menu display appears.

Up/down-keys Each press of the up-key increments or advances the values or settings on the no. 2 display, while each press
of the down-key decrements or returns the values or settings on the no. 2 display.

E.g. in the normal run situation setpoints can be changed by pressing up or down keys.

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11.1 Operation

Parameter settings are done by Auramarine Ltd. according to the lists

below.

After power is switched on, controller starts to operate. Setpoint can be

changed by pressing up or down key. Viscosity controller uses mPas and
temperature controller ºC.

Manual operation is executed by first pressing A/M key (MANU lits) and
then operating with up key and down key. Return to auto operation by
pressing A/M key (MANU goes out).

Controller can be auto tuned by setting the setting of the parameter At

from Level 1 to AT-2. Auto tuning can be cancelled by setting the setting
of the parameter At to OFF.

Ensure the operation of viscosity/temperature controller, if they are not

installed to local control panel by Auramarine Ltd.

a) Switch viscometer and booster pump on.

b) If there is HFO/LFO, MDO valve in feeder/booster unit,
turn it to HFO position.
c) Open steam/thermal oil valves or switch electric heater on
by control switch at local control panel.
d) Choose controller by control switch at local control panel.
e) Set setpoint above process value. Control valve should
open or stages of electric heater should increase power.
f) Set setpoint below process value. Control valve should
close or stages of electric heater should decrease power.
g) In case of malfunction, check wiring.
h) Set setpoint to normal and viscosity control on.

In case of trouble, the following should be checked:

1) Connections are done according to the electrical drawings.

2) Controller is supplied with AC 100...240 V 50/60 Hz.
3) Transmitter of process value gives correct signal. Signal
error is displayed in no.1 display "S.Err".
4) Parameter settings are according to the lists below.

In case of process value hunting, it is recommended to increase the

setting of the parameter I (integral time) at level 1. If it does not help, it is
recommended to increase also the setting of the parameter P
(proportional band) at level 1.

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11.2 Access to parameters

Power on
Process value is shown in no. 1 display
Setpoint is shown in no. 2 display

By pressing display key at least one

second
"Menu" appears to no. 1 display
"Lv-0" appears to no. 2 display

By pressing display key at least one

second
"Menu" appears to no. 1 display
"Lv-1" appears to no. 2 display

By pressing up-key
"Lv-1 appears to no. 2 display

By pressing display key at least

one second
"At"(parameter) appears to no. 1 display
"off"(setting) appears to no. 2 display

Moving from a parameter to an other is

done by a quick press of display key
Setting change of a parameter is
done by up or down key

By pressing display key at least one

second
"Menu" appears to no. 1 display
"Lv-1" appears to no. 2 display

By pressing down key

"Lv-0 appears to no. 2 display

By pressing display key at least one

second
Process value appears to no. 1 display
Setpoint appears to no. 2 display

Protect mode is set to 3 to allow changes only at levels 0 and 1, and it is not
recommended to go any other levels.

Access to other levels by pressing A/M key and display key simultaneously at
least one second until "SECr" appears to no. 1 display and then changing 3 to1
to no. 2 display by pressing down key. Exit from protect mode is done by
pressing A/M key and display key simultaneously at least one second.

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11.3 Parameter settings of the viscosity controller A16A1

If setting colum is empty default is used.
Mode Parameter Name Setting Range Unit Default Remarks Setting
SECr Security 0 to 6 None 1 3
Protect
KEYP [A/M] key protect ON/OFF None OFF
Manual Manual MV -5.0 to 105.0 *1 % 0.0
Set Point Set point lower limit to Set point upper limit EU 0
Level 0
r-s Run/Stop Run/Stop None Run
AT AT Execute/Cancel OFF/AT-1/AT-2 None OFF During running
SP-0 Set point 0 Set point lower limit to Set point upper limit EU 0 Multi-SP
SP-1 Set point 1 Set point lower limit to Set point upper limit EU 0 Multi-SP
SP-2 Set point 2 Set point lower limit to Set point upper limit EU 0 Multi SP
SP-3 Set point 3 Set point lower limit to Set point upper limit EU 0 Multi-SP
AL-1 Alarm value 1 -1999 to 9999 EU 0 3
AL-2 Alarm value 2 -1999 to 9999 EU 0 3
AL-3 Alarm value 3 -1999 to 9999 EU 0
P Proportional
0.1 to 999.9 %FS 10.0 10
band
I Integral time 0 to 3999 sec 233 240
d Derivate time 0 to 3999 sec 40 0
Level 1
C-SC Cooling coefficient At heating and
0.01 to 99.99 None 1.00 cooling control
C-db Dead band At heating and
-19.99 to 99.99 %FS 0.00 cooling control
At position-
Db Position-proportional dead band 0.1 to 10.00 % 2.0 proportional control 0.3
mF-r Manual reset value 0.0 to 100.0 % 50.0
HYS Hysteresis (heat) 0.01 to 99.99 %FS 0.10
CHYS Hysteresis (cool) At heating and
0.01 to 99.99 %FS 0.10 cooling control
CP Control period
1 to 99 sec 20
(heat)
C-CP Control period (cool) At heating and
1 to 99 sec 20 cooling control
Hb Heater burnout Heater burnout
0.0 to 50.0 A 0.0 detection
r-L Remote/Local Communications
RMT/LCL None LCL units settings
SPmd SP mode RSP/LSP None LSP
SPrU SP ramp time unit M(Minutes) / H(Hours) None M
SPrs SP ramp set value 0 to 9999 EU 0
LBA LBA detection time 0 to 9999 *1 sec 0
mv-S MV at stop -5.0 to 105.0 *1 % 0.0 HOLD
mv-E MV at PV error -5.0 to 105.0 *2 % 0.0 HOLD
ML-H MV upper limit MV lower limit + 0.1 to 105.0 *3 % 105.0
ML-L MV lower limit -5.0 to MV upper limit –0.1 % -5.0
Level 2 MrL MV change rate
0.0 to100.0 %/sec 0.0
limit
InF Input digital filter 0 to 9999 sec 0
OC-H Open/close
0.1 to 20.0 % 0.8 0.5
hysteresis
ALH1 Alarm 1 hysteresis 0.01 to 99.99 % 0.02 1.0
ALH2 Alarm 2 hysteresis 0.01 to 99.99 % 0.02 1.0
ALH3 Alarm 3 hysteresis 0.01 to 99.99 % 0.02
InSH Input shift upper
-199.9 to 999.9 ºC/ºF 0.0 Temperature input
limit
InSL Input shift lower
-199.9 to 999.9 ºC/ºF 0.0 Temperature input
limit
*1During heat and cooling control, the lower limit becomes –105.5%. During position-proportional control the setting becomes
HOLD, OPEN or CLOSE. *2 During heat and cooling control, the setting range becomes 0.0 to 105.0%. *3 During heat and
cooling control, the setting range becomes –105.0 to 0.0%.

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Mode Parameter Name Setting Range Unit Default Remarks Setting

In-T Input type 0 to 21 None 2 17
In-H Scaling upper limit Scaling lower limit +1 to 9999 *4 EU -100 Analog input 50
-1999 to SP setting upper limit
In-L Scaling lower limit EU 0 Analog input 0
0.1*4
dP Decimal point 0 to 3 None 0 Analog input
d-U ºC/ºF selection ºC/ºF None ºC Temperature input
InIT Parameter initialize Yes/No None No
OUT1 Control output 1 assignment Heat/Cool/Alarm1/Alarm2/Alarm3/HBA/LBA None HEAT
OUT2 Control output 2 assignment Heat/Cool/Alarm1/Alarm2/Alarm3/HBA/LBA None AL-1
Alarm1/Alarm2/Alarm3/HBA/LBA/
SUB1 Auxiliary output1 assignment
S.ERR/E333/RSER None AL-2 AL1
Setup Alarm1/Alarm2/Alarm3/HBA/LBA/
SUB2 Auxiliary output 2 assignment
S.ERR/E333/RSER None AL-3 AL2
Output assignment
ALT1 Alarm 1 type 1 to 11 None 2 needer 3
Output assignment
AL1n Alarm 1 open in alarm N-O/N-C None N-O needer N-C
Output assignment
ALT2 Alarm 2 type 1 to 11 None 2 needer 2
Output assignment
AL2n Alarm 2 open in alarm N-O/N-C None N-O needer N-C
Output assignment
ALT3 Alarm 3 type 1 to 11 None 2 needer
Output assignment
AL3n Alarm 3 open in alarm N-O/N-C None N-O needer
Drev Direct / Reverse operation OR-R/OR-D None OR-R OR-D
SL-H Set point upper limit Set point lower limit +1 to scaling upper limit *2 None 1300 *4 50
SL-L Set point lower limit Scaling lower limit to Set point upper limit –1 *2 None -200 *4 0
CnTL PID/ON/OFF PID/ON/OFF None PID
ST ST OFF/ON None OFF
ST-b ST stable range 0.1 to 999.9 ºC/ºF 15.0 ST=ON
Expan- ALFA α 0.00 to 1.00 None 0.65
sion AT-G AT calculated gain 0.1 to 10.0 None 1.0
ReSm Standby sequence reset setting 0/1 None 0
method
ReM Automatic return of display
0 to 99 Sec 0 30
mode
AT-H AT hysteresis 0.1 to 9.9 %FS 0.2 0.2
LBAB LBA detection width 0.0 to 999.9 %FS 0.2
*4 When temperature input is selected, the sensor range selected in the ”input type”
parameter (setup mode) correspond to the scaling upper and lower limit value.

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Mode Parameter Name Setting Range Unit Default Remarks Setting

EV-M Multi-SP function 0 to 2 None 0
EV-1 Event input assignment 1 NON/STOP/RMT/MAN/RSP None NON
EV-2 Event input assignment
NON/STOP/RMT/MAN/RSP None NON
2
SbCT Communication stop bit 1/2 bits 2
Len Communication data length 7/8 bits 7
Prty Communication parity None/Even/Odd None EVEN
BPS Communication baud
1.2/2.4/4.8/9.6/19.2 kbps 9.6
value
U-no Communication unit No. 0 to 99 None 0
Tr-T Transfer output type SP/SP-M/PV/O/C-O/V-M None SP
Option Tr-H Transfer output upper
*5 *5 *5
limit
Tr-L Transfer output lower
*5 *5 *5
limit
HbL HBA latch ON/OFF None OFF
CALb Motor calibration ON/OFF None OFF
MoT Travel time 1 to 999 Sec 1
P-db PV dead band 0 to 9999 EU 0
rSPU Remote SP enable ON/OFF None OFF
SP setting lower limit to SP setting upper
rSPH Remote SP upper limit limit EU 1300
SP setting lower limit to SP setting upper
rSPL Remote SP lower limit limit EU -200
SPTr SP tracking ON/OFF None OFF
*5 Set the transfer output type parameter according to the following table.

Transfer Output Type Transfer Output Lower Limit to Transfer Output Upper Limit
SP :Set point Set point lower limit to Set point upper limit
SP-M :Set point during SP ramp Set point lower limit to Set point upper limit
PV :Process value Scaling lower limit to scaling upper limit
O :Manipulated variable(heat) -5.0 to 105.0%
C-O :Manipulated variable(cool) 0.0 to 105.0%
V-M :Value opening -10.0 to 110.0%
• Default : SP
• The output ranges of the SP settings, set point or process value when temperature input is selected are the ranges
supported by the selected sensor.
• When the heating side manipulated variable or cooling side manipulated variable is selected, the transfer output lower
limit in a heating and cooling control becomes 0.0.

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11.4 Parameter settings of the temperature controller A16A2

If setting column is empty default is used.
Mode Parameter Name Setting Range Unit Default Remarks Setting
SECr Security 0 to 6 None 1 3
Protect
KEYP [A/M] key protect ON/OFF None OFF
Manual Manual MV -5.0 to 105.0 *1 % 0.0
Set Point Set point lower limit to Set point upper limit EU 0
Level 0
r-s Run/Stop Run/Stop None Run
AT AT Execute/Cancel OFF/AT-1/AT-2 None OFF During running
SP-0 Set point 0 Set point lower limit to Set point upper limit EU 0 Multi-SP
SP-1 Set point 1 Set point lower limit to Set point upper limit EU 0 Multi-SP
SP-2 Set point 2 Set point lower limit to Set point upper limit EU 0 Multi SP
SP-3 Set point 3 Set point lower limit to Set point upper limit EU 0 Multi-SP
AL-1 Alarm value 1 -1999 to 9999 EU 0 10
AL-2 Alarm value 2 -1999 to 9999 EU 0 10
AL-3 Alarm value 3 -1999 to 9999 EU 0
P Proportional band 0.1 to 999.9 %FS 10.0 2
I Integral time 0 to 3999 sec 233 240
d Derivate time 0 to 3999 sec 40
Level 1 At heating and
C-SC Cooling coefficient 0.01 to 99.99 None 1.00 cooling control
C-db Dead band At heating and
-19.99 to 99.99 %FS 0.00 cooling control
Db Position-proportional dead At position-
0.1 to 10.00 % 2.0 proportional control 0.8
band
mF-r Manual reset value 0.0 to 100.0 % 50.0
HYS Hysteresis (heat) 0.01 to 99.99 %FS 0.10
CHYS Hysteresis (cool) At heating and
0.01 to 99.99 %FS 0.10 cooling control
CP Control period (heat) 1 to 99 sec 20
C-CP Control period (cool) At heating and
1 to 99 sec 20 cooling control
Hb Heater burnout Heater burnout
0.0 to 50.0 A 0.0 detection
r-L Remote/Local Communications
RMT/LCL None LCL units settings
SPmd SP mode RSP/LSP None LSP
SPrU SP ramp time unit M(Minutes) / H(Hours) None M
SPrs SP ramp set value 0 to 9999 EU 0
LBA LBA detection time 0 to 9999 *1 sec 0
mv-S MV at stop -5.0 to 105.0 *1 % 0.0 HOLD
mv-E MV at PV error -5.0 to 105.0 *2 % 0.0 HOLD
ML-H MV upper limit MV lower limit + 0.1 to 105.0 *3 % 105.0
Level 2 ML-L MV lower limit -5.0 to MV upper limit –0.1 % -5.0
MrL MV change rate limit 0.0 to100.0 %/sec 0.0
InF Input digital filter 0 to 9999 sec 0
OC-H Open/close hysteresis 0.1 to 20.0 % 0.8 0.5
ALH1 Alarm 1 hysteresis 0.01 to 99.99 % 0.02 0.25
ALH2 Alarm 2 hysteresis 0.01 to 99.99 % 0.02 0.25
ALH3 Alarm 3 hysteresis 0.01 to 99.99 % 0.02
InSH Input shift upper limit -199.9 to 999.9 ºC/ºF 0.0 Temperature input
InSL Input shift lower limit -199.9 to 999.9 ºC/ºF 0.0 Temperature input
*1During heat and cooling control, the lower limit becomes –105.5%. During position-proportional control the setting
becomes HOLD, OPEN or CLOSE. *2 During heat and cooling control, the setting range becomes 0.0 to 105.0%. *3 During
heat and cooling control, the setting range becomes –105.0 to 0.0%.

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Mode Parameter Name Setting Range Unit Default Remarks Setting

In-T Input type 0 to 21 None 2 1
In-H Scaling upper limit Scaling lower limit +1 to 9999 *4 EU -100 Analog input
In-L Scaling lower limit -1999 to SP setting upper limit 0.1*4 EU 0 Analog input
dP Decimal point 0 to 3 None 0 Analog input
d-U ºC/ºF selection ºC/ºF None ºC Temperature input
InIT Parameter initialize Yes/No None No
OUT1 Control output 1 assignment Heat/Cool/Alarm1/Alarm2/Alarm3/HBA/LBA None HEAT
OUT2 Control output 2 assignment Heat/Cool/Alarm1/Alarm2/Alarm3/HBA/LBA None AL-1
Alarm1/Alarm2/Alarm3/HBA/LBA/
SUB1 Auxiliary output1 assignment
S.ERR/E333/RSER None AL-2 AL1
Setup SUB2 Auxiliary output 2 assignment
Alarm1/Alarm2/Alarm3/HBA/LBA/
None AL-3 AL2
S.ERR/E333/RSER
Output assignment
ALT1 Alarm 1 type 1 to 11 None 2 needer 3
Output assignment
AL1n Alarm 1 open in alarm N-O/N-C None N-O needer N-C
Output assignment
ALT2 Alarm 2 type 1 to 11 None 2 needer 2
Output assignment
AL2n Alarm 2 open in alarm N-O/N-C None N-O needer N-C
Output assignment
ALT3 Alarm 3 type 1 to 11 None 2 needer
Output assignment
AL3n Alarm 3 open in alarm N-O/N-C None N-O needer
Drev Direct / Reverse operation OR-R/OR-D None OR-R
SL-H Set point upper limit Set point lower limit +1 to scaling upper limit *2 None 1300 *4
SL-L Set point lower limit Scaling lower limit to Set point upper limit –1 *2 None -200 *4
CnTL PID/ON/OFF PID/ON/OFF None PID
ST ST OFF/ON None OFF
ST-b ST stable range 0.1 to 999.9 ºC/ºF 15.0 ST=ON
Expan- ALFA α 0.00 to 1.00 None 0.65
sion AT-G AT calculated gain 0.1 to 10.0 None 1.0
ReSm Standby sequence reset setting
0/1 None 0
method
ReM Automatic return of display
0 to 99 Sec 0 30
mode
AT-H AT hysteresis 0.1 to 9.9 %FS 0.2
LBAB LBA detection width 0.0 to 999.9 %FS 0.2
*4 When temperature input is selected, the sensor range selected in the ”input type”
parameter (setup mode) correspond to the scaling upper and lower limit value.

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Mode Parameter Name Setting Range Unit Default Remarks Setting

EV-M Multi-SP function 0 to 2 None 0
EV-1 Event input assignment 1 NON/STOP/RMT/MAN/RSP None NON
EV-2 Event input assignment 2 NON/STOP/RMT/MAN/RSP None NON
SbCT Communication stop bit 1/2 bits 2
Len Communication data
7/8 bits 7
length
Prty Communication parity None/Even/Odd None EVEN
BPS Communication baud
1.2/2.4/4.8/9.6/19.2 kbps 9.6
value
U-no Communication unit No. 0 to 99 None 0
Option Tr-T Transfer output type SP/SP-M/PV/O/C-O/V-M None SP
Tr-H Transfer output upper limit *5 *5 *5
Tr-L Transfer output lower limit *5 *5 *5
HbL HBA latch ON/OFF None OFF
CALb Motor calibration ON/OFF None OFF
MoT Travel time 1 to 999 Sec 1 120
P-db PV dead band 0 to 9999 EU 0 1
rSPU Remote SP enable ON/OFF None OFF
SP setting lower limit to SP setting upper
rSPH Remote SP upper limit limit EU 1300
SP setting lower limit to SP setting upper
rSPL Remote SP lower limit limit EU -200
SPTr SP tracking ON/OFF None OFF
*5 Set the transfer output type parameter according to the following table.

Transfer Output Type Transfer Output Lower Limit to Transfer Output Upper Limit
SP :Set point Set point lower limit to Set point upper limit
SP-M :Set point during SP ramp Set point lower limit to Set point upper limit
PV :Process value Scaling lower limit to scaling upper limit
O :Manipulated variable(heat) -5.0 to 105.0%
C-O :Manipulated variable(cool) 0.0 to 105.0%
V-M :Value opening -10.0 to 110.0%
• Default : SP
• The output ranges of the SP settings, set point or process value when temperature input is selected are the ranges
supported by the selected sensor.
• When the heating side manipulated variable or cooling side manipulated variable is selected, the transfer output lower
limit in a heating and cooling control becomes 0.0.

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12 PRESSURE SWITCH MBC 5000, 5100

Electrical connection

Mechanical connection

Adjustment

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13 LEVEL LIMIT SWITCH LIQUIPHANT T FTL20

The device may be installed, connected, commissioned, operated

and maintained by qualified and authorised personnel only.

Do not bend

Do not shorten

Do not lenghen

13.1 Instructions

1 Handling
Hold by the housing, not by the sensor fork

2. Take account of viscosity and build-up

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3. Align sensor fork Note mark ▼

4. Test with test magnet

5. Cleaning

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14 FLOW METER TYPE B-SERIES

14.1 Start-up procedures

Before initial start-up of a flow meter system, or when taking the

installation again into use after a major repair or revision of piping
system, the following procedures are recommended.

1. Remove filter element of liquid filter installed ahead of flow meter

2. Remove flow meter from liquid system and replace it by a pipe piece.
3. Flush entire liquid system to ensure that all dirt and other foreign
matter that could damage the flow meter have been removed.

Do not flush ductile iron flow meters with water.

Never exceed maximum flowrate (Qmax, see text plate of flow

meter).

When re-starting the flow meter measures must taken to avoid the
presence of solidified or cured liquids inside the flow meter. Failure
to do so may result in braking of the magnet or magnet shaft.

Fig. 1 Flow meter system with bypass

14.2 Initial start-up of a flow meter system with bypass:

1. Close valves A, B and C (Fig. 1)

2. Remove flushing pipe piece. Re-install flow meter and filter element
3. Start pump and/or open storage tank valve
4. Slowly open bypass valve C completely
5. Open valve A slightly (5-10%)
6. Slowly open valve B. Dependent on the internal resistance in the
system, the flow meter may start running. If it does, limit the flow to
approx. 20% of its capacity.

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7. Slowly close bypass valve C until flow meter just starts running. Let the
flow meter run on this limited flow for a couple of minutes, to ensure
that no air or gas will be left in the flow meter.
8. Slowly open valve A, and if necessary also valve B, completely.
9. Slowly close valve C completely.

Never exceed maximum flowrate (Qmax, see text plate of flow

meter)

14.3 Initial start-up of a flow meter system without bypass

1. Close valves A and B (Fig. 2).

2. Remove flushing pipe piece. Re-install flow meter and filter element.
3. Start pump and/or open storage tank valve.
4. Open valve A slightly (5-10%).
5. Slowly open vah'e B until flow meter just starts running. Let the meter
run on this limited flow for a couple of minutes, to ensure that no air
or gas will be left in the flow meter.
6. Slowly open valve B completely.
7. Slowly open valve A completely.

Never exceed maximum flowrate (Qmax, see text plate of flow

meter)

Filter meter

Flushing piece

Fig 2 Flow meter system without bypass

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14.4 Maintenance

14.4.1 General

Under normal operating conditions the flow meter requires no

maintenance other than:

ƒ Periodic accuracy check.

ƒ Check of totaliser (if this option is supplied)

14.4.2 Accuracy check

The calibration interval will depend on the nature of the process liquid
and the operating conditions. The table below applies if

ƒ the process liquid is clean and non-abrasive;

ƒ a liquid filter with correct mesh width has been installed at the
flow meter inlet.

Meter type Calibration interval (litres)

B5015 11 x 106
B5023 11 x 106
B5025 35 x 106
B5040 55 x 106
B5050 110 x 106

14.4.3 Check of the totaliser

The totaliser should be inspected

- every two years when the flow meter is installed in a normal

environment;
- every year when the flow meter is installed in a hot, humid or dusty
environment.

To check counter:

1. Remove three cross head screws and lift off cap.

2. Inspect gear train for wear.

Be sure not to damage any pulse generators. Dot not lubricate

plastic parts.

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14.4.4 To remove flow meter from piping system

When removing a flow meter from the piping system precautions must be
taken to prevent personal injuries and damage to the flow meter and
process control installation.

The flow meter body will maintain the same temperature as the
process liquid. Take measures to avoid personal injury from
touching a hot or cold flow meter.

Always wear protective clothing when the flow meter contains a

toxic or aggressive fluid.

Support the flow meter when removing it from the process piping.

1. Shut off flow through flow meter.

2. Remove any electrical connections from flow meter.
3. Empty piping system
4. Drain flowmeter.
5. Remove flowmeter from piping system.

Do not empty piping system by blowing through with steam or air,

otherwise flow meter will be overspeeded.

6. If the flowmeter is fitted with a drain plug, remove plug to empty

flowmeter.

When the flow meter is removed from the piping system there will
still be some liquid left in its measuring chamber.

7. Hold meter outlet in downward position and let flow meter leak out for
approximately ten minutes. High viscosity liquids will perhaps require
more time. Rinsing with a suitable solvent may be of help.
8. If the flow meter must be stored or returned to Auramarine Ltd:
a. Flush flow meter with a non-toxic, non-aggressive fluid
b. Plug inlet and outlet ports of flow meter
c. Clean the flow meter externally and internally. It must be free from
risks of fire, explosion and toxic matters which may cause a
hazardous situation or personal injury.

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14.4.5 To remove counter from flowmeter

Remove pulse box or counter from meter body according the following
procedure:
1. Loosen 4 bolts M4 x 12
2. Rotate outer magnet with finger and check shafts, calibration gears
and bearings for wear and excessive slackness of the counter drive.
3. Ensure that the outer magnet is clean and that none of the magnets
are missing or damaged. Check centering of outer magnet.

Fig 3 N-counter Fig 4 Pulse box

14.4.6 To remove magnet cap and magnet

1. Remove magnet cap holder by loosening the nut

2. Remove magnet cap, inner magnet and sealing ring
3. Check inside of magnet cap and outside of inner magnet for grooves.
If any grooves are found, the magnet shaft is probably bent and must
be replaced. Replace the magnet cap if too heavily grooved.

Fig 5-7 Magnet cap

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14.4.7 To remove front cover

Register the flowdirection before dismantling the flowmeter. Look from

counter side to arrow marked at the flowmeter for flow direction.

NOTE: Standard flow direction is left to right.

Check for any signs of bearing wear by 'wiggling' flow meter shaft
carefully.
1. Remove the front cover mounting bolts and lock washers (Fig 8)
2. Install the bolts, which were removed in step 1 above, in the jacking
positions of the front cover (Fig 9). Tighten these bolts evenly and
alternately until the cover frees. Ensure cover is lifted equally to
protect the location pins from being damaged.
3. Lift off cover equally to protect the location pins from being damaged
and remove bolts and O-ring (Fig 10). Visually inspect inside surface
and bearing cavity for grooves and other signs of wear, indicating that
bearing(s) or vanes are damaged.

Fig 8 Fig 9 Fig 10

Do not remove the pin glued in the cover while it is used for
centering the cover.

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14.4.8 To remove rotor/vanes assembly

1. Before taking the rotor out of the meter body, visually inspect the
inside of the body to locate possible cause of damage. If the vanes
appear to be broken, ensure that the vane push rods will not scratch
against the inner wall of the meter body, when the rotor is pulled out
(fig 11).
2. Record how vanes are Installed in the rotor (figure 12). Remove rotor
from body by gently pulling at the rotor shaft and supporting the
rotor/vane assembly with the other hand (figure 13)

Fig 11 Fig 12 Chamfered edge L Æ R and L ÅR

Fig 13

Be careful not to drop or damage the four loose vanes and the two
loose vane push rods when removing the rotor from the meter
body. Keep both pairs of vanes together.

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14.4.9 To remove back cover

1. Remove the back cover mounting bolts and lock washers (figure 14)
2. Install the bolts, which were removed in step 1 above, in the jacking
positions of the back cover (figure 15). Tighten these bolts evenly and
alternately until the cover frees. Ensure cover is lifted equally to
protect the location pins from being damaged.
3. Lift off cover and remove bolts and O-ring (figure 16). Visually inspect
inside surface and bearing cavity for grooves and other signs of wear,
indicating that bearing(s) or vanes are damaged.

Fig 14 Fig 15

Fig 16

14.4.10 To inspect inside of meter body

1. Visually inspect inner surface of meter body for grooves. Minimal

grooving due to small impurities in the process liquid requires no
further action, provided that the original shape of the metering
chamber is not disturbed. Grooving caused by course particles in the
process liquid, or by a vane push rod when a vane is broken, will
upset material. Such obstructions may result in uneven running of the
flow meter and/or premature vane wear affecting the performance of
the flow meter.
2. Remove any surface roughness with fine emery cloth.

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NOTE: If the meter wall was heavily scored no guarantee can be

given that after polishing action the flowmeter will still be
able to operate within its specified limits of accuracy.

3. Degrease meter body in a suitable solvent.

14.4.11 To inspect rotor and vanes

1. Visually inspect for chipped vanes, replace vanes if necessary.

2. Measure the height of vanes. Replace vanes if height is less than
height of rotor.
3. Measure the vane/slot clearance using a feeler gauge (fig 17). For
correct measurement the gauge must be bottomed out in the slot. If
the tolerance shown below is exceeded, the vane(s) must be
replaced.

Meter model Standard vane - slot clearance

[mm]
B5015 (1/2") 0.040-0.050
B5025 0") 0.040 - 0.070
B5040 (2") 0.040 - 0.070
B5050 (2") 0.045 - 0.080

4. Check that the vane at vane rod side is not damaged causing too
much space between vanes and meter body.
5. Check that the vane rods can slide freely in and out of the rotor. If the
rods can not move freely this may be caused by dirt, worn out bores,
bent push rods ore scored vanes. Any defective parts must be
replaced.

Fig 17

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14.4.12 To inspect bearings and rotor shaft

1. Visually inspect bearings, bearing cages, bearing cavities in covers

and rotor shaft for excessive wear or other damage. The maximum
run out tolerance for rotor shafts is 0.01 mm dial gauge reading.
2. Replace defective bearings.

14.4.13 To replace bearings

1. Remove old bearing from rotor shaft using a suitable bearing puller
(Figure 18).

NOTE: Because the space between bearings and rotor is

approximately 2 mm, this operation requires a puller with thin
blades.

Press new bearing vertically on rotor shaft using an arbor press.

Fig 18

14.4.14 To re-assemble a flowmeter

1. If there is any doubt about the condition of a particular flow meter

component, replace it when the meter is still dismantled. This is more
economical than having to strip the flow meter down again after a
short period of time.
2. Once the flow meter has been dismantled it is recommended that the
O-rings for the covers and the O-ring for the magnet cap are
replaced.
3. Metal and carbon parts must be degreased before assembly. O-rings
should only be wiped dry with a clean cloth.

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14.4.15 To install back cover

1. Clean O-ring groove and install new O-ring (Figure 19).

2. Position back cover over locating pins of meter body.

Fig 19

Take utmost care not to damage the locating pins. Ensure that the
O-ring remains in place and is not damaged while tapping down
cover.

4. Install cover to meter body using bolts (and lock washers if originally
provided). Lubricate bolt threads with 'Never Seez'. Tighten bolts
alternately and evenly to the torque value specified on table.

Torque values (Nm) — Covers

Meter Model No. Of bolts Stainless Steel Steel Ductile iron

B5015 6xM6 - - 8.5- 9
B5025/B5040 6xM6 - - 8.5- 9
B5050 6xM8 - - 16-17

To install rotor and vanes

1. Place the two vane push rods through the drilled and reamed holes in
the rotor (Figure 20).
2. Place rotor with installed vane push rods into flow meter body, with
magnet shaft facing up (Figure 21).

Take care not to damage the bearing in the back cover.

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3. Place two opposite slots in rotor in line with inlet and outlet flange
connections of flow meter.

Fig 20 Fig 21

4. Insert the four (4) vanes one by one into the slots of the rotor, starting
with the vane nearest to the inlet connection. Continue with the
opposite vane. Then rotate the rotor 1/4 turn and insert the other
vanes in the same order (Figure 22). The chamfered edge of each
vane must be in the rotating direction of the rotor, as shown in Figure
23 for flow meters with flow direction from left to right and from right
to left. The top of the vanes must be flush with the upper surface of
the rotor.

Take care not to damage the vanes.

Fig 22 Fig 23 Chamfered edge L Æ R and L Å R

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5. Measure the radial vane clearance with a feeler gauge. Measurement

should be taken as shown in Figure 24, For correct measurement the
gauge must be bottomed out in the slot. If the tolerance is in excess
of the value mentioned in the table, replace vane(s) or grind to size
with fine emery cloth

Fig 24

6. Rotate the rotor with finger to ensure that it will run smoothly.

Vane-to-meter body clearance

Model No Tolerance (mm)
B5015 (1/2”) 0.025 – 0.060
B5025 (1”) 0.040 – 0.090
B5040 (1.5”) 0.040 – 0.090
B5050 (2”) 0.050 – 0.100

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14.4.16 To install front cover to meter body

1. Clean O-ring groove and install new O-ring.

2. Tilt meter body, so that the rotor shaft is in horizontal position.
3. Position front cover over locating pins on meter body.

When installing front cover to meter body take utmost care not to
damage bearing and locating pins. Ensure that the O-ring remains
in place and is not damaged.

4. Lubricate threads of cover mounting bolts with 'Never Seez1. Install

bolts (and lock washers if originally provided). Tighten bolts equally
and in turn (Figure 25), in accordance with the torque value table.

Fig 25

14.4.17 To install inner magnet

1. Place inner magnet on rotor shaft (Figure 26). The magnet should be
placed as shown in figure 27. The magnet must be flush with the
shaft.
2. With the rotor shaft in horizontal position, rotate the rotor shaft by
hand using the magnet to check that the rotor runs smoothly.

Fig 26 Fig 27

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14.4.18 To install magnet cap

1. Clean O-ring groove in front cover and install new O-ring (Figure 28).
2. Clean inner magnet with compressed air.
3. Place magnet cap over magnet (Figure 29)
4. For a final check that the rotor runs smoothly after assembling covers
and magnet cap, the flow meter may be blown through with
compressed air at low pressure. The rotor must then be able to make
a few obstructionless rotations. If the rotor does not run smoothly,
disassemble the flow meter and repeat the assembly procedures.

Extreme care should be taken not to overspeed the rotor to avoid

damage to the internal meter parts. Just apply enough air that the
rotor starts running.

Fig 28 Fig 29

14.4.19 To install pulse transmitter box or counter

Clean outer magnet of pulse transmitter box/counter.

Install the pulse transmitter box/counter by placement of the four bolts
M4x12.

NOTE: The pulse transmitter box must be installed in such a way

that, when the flow meter is installed in the liquid piping, the
cable gland will point downwards or side wards, but never
upwards.

14.4.20 Final performance check

If the flow meter is recalibrated during a maintenance check or after

replacement of major parts, the highest measuring accuracy should be
within the operating flow range of the flow meter.

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14.5 Trouble shooting

Possible cause
Problem (perform a check in Solution
the following order):
The flow meter does 1. The valve in the bypass Close bypass valve.
not indicate any flow, line is still open
although the liquid is 2. The totaliser or FlowCount Totaliser:
flowing. Rate- Totaliser is Remove counter drive shaft
malfunctioning. with finger to see if counter
runs smoothly.
FlowCount: Is battery empty
?
Refer to trouble shooting
section of manual supplied
with instrument
Continue with next step if this
does not solve the problem.
3. Inner parts of flow meter Return flow meter to
may be stuck or broken. Auramarine Ltd.
The flow meter does 1. Obstructions in the liquid Check for obstructions, e.g.
not indicate any flow piping, blocking the flow. closed valves. If this does
and no liquid is not solve the problem,
passing through the proceed with next step
flow meter. 2.The dust cap in the inlet Remove dust cap(s) and
and/or outlet connection of check the flow meter
for the flow meter was not damage. If there are no
removed when the flow visible signs of damage,
meter was installed in the proceed with next step.
process line.
3. Dirt is blocking the inner Flush the flow meter with a
parts of the flowmeter. suitable solvent.
If this does not solve the
problem, return flow meter to
Auramarine Ltd

4. Inner parts of flow meter Return flow meter to

may be stuck or broken. Auramarine Ltf

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14.6 Optional pulse transmitter

If the flow meter is equipped with a totaliser, the internal connections of

the cable connected to the flow meter are as shown in figure below. The
number of generated output pulses/litre is stamped on the dataplate of
the totaliser.

6-pole Cable
connector
High 1 + A White
B Green
High 2 + C Brown
D Yellow
Low 1 + E Brown
F Yellow
Low 2 + C White
D Green

Fig 30 Right- Fig 31 Straight

angled 6-pins 6-pins plug
plug

If the flow meter is equipped with a pulse transmitter box (instead of a

totaliser), the number of generated output pulses is stamped on the
dataplate of the pulse transmitter box.

brown+ white+*
Wiring of pulse generators: yellow- green-

Connections of pulse transmitter

1 low frequency puke

low:

1 high frequency pulse

high:

1 low + high frequency pulse

low: high:
transmitter

2 low frequency pulse transmitters* low: low:

2 high frequency pulse transmitters high: high:

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Technical specification of pulse transmitters

Inductive type: 1 or 2 passive proximity switches according DIN

19234 (NAMUR). Protection class IP55, intrinsically
safe acc. PTB No.99 ATEX 2219X and Cenelec Eex
ia/ib lic T6, if used with suitable zene-barrier. Max.
operating temperature 75°C. Supply voltage 8.2
VDC.
Incremental type: Installed in a pulse box fitted to the flow meter.
Includes pulse discriminator. Supply voltage 12-35
VDC. Max frequency 5 kHz. Protection class IP55.
Max. operating temperature 120°C.

Intrinsic safe operation

To meet the standards for intrinsically safe operation according DIN

19234 (NAMUR), zener-barrier(s) (Stahl 9001/3-158-150/00, Pepperl &
Fuchs EGT -101-0, or equivalent) must be installed between the flow
meter and the associated data processing instrumentation.

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14.7 Optional pulse discriminator

The pulse discriminator is housed in the pulse transmitter box of a non-

indicating flow meter. The discriminator is used in situations where, as a
result of vibrations or pulsations in the liquid piping, it is possible for the
flow meter to rotate in the reverse direction. This may result in the
generation of spurious pulses by the electric transmitter. By using a
double pulse transmitter in the flow meter, generating two identical pulse
signals with a phase shift of 90 degrees, these measurement errors will
be eliminated by means of the pulse discriminator. The discriminator
comprises a small printed circuit board which also contains a pulse
amplifier. This makes the device suitable for direct connection to, for
instance, an electromechanical counter or to a relay for further pulse
processing.

Electric connections: 3-wire screw terminal

Supply voltage: 12-35 VDC
Power consumption: 2 V A at 35 VDC (no load)
Input signal: 2 NAMUR pulse transmitters or incremental encoders
Pulse memory: up to 15 fault pulses
Connections 6-pin connector or cable gland PO 13.5
Max. working temp: 55°C
Output signal: Open collector, current sink .Imax 100 mA, Umax 35 VDC
Protection class: IP55, DIN 40050
Approved: CE

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15 VISCOMASTER TYPE 7829

DO NOT drop it

DO NOT use liquids incompatible with materials of construction.

DO NOT operate the ViscoMaster above its rated pressure.

DO NOT operate above rated maximum temperature.

DO NOT pressure test beyond the specified test pressure.

ENSURE all explosion proof requirements are applied

ENSURE transmitter and associated pipework are pressure tested

to 1½ times the maximum operating pressure after installation.

ALWAYS store and transport the ViscoMaster in its original

packaging.

15.1 Viscomaster measurements

The ViscoMaster directly measures the following fluid properties:

• Line dynamic viscosity(measured in centiPoise - cP)

• Line Density(measured in kg/m3, g/cc, lb/gal, or lb/ft3)
• Temperature(measured in °C or °F)

From these properties, ViscoMaster calculates:

• Line kinematic viscosity(measured in centiStokes - cSt)

• Base (referred) density (API)Referral is made to 15°C, 1.013bar; or at
60°F, 14.5psi

15.2 During a normal run

Observe and record the normal operating temperatures and viscosity

readings. (You can monitor the system using ADView). When several
systems are run in parallel and use the same fuel source, comparison of
the readings between installations can be a useful indicator of possible
system faults. Differences between readings, or changes from the
normally observed conditions, should always be investigated to confirm
that instrumentation is functioning correctly.

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Particular attention should be paid to the conditions before and after

engine shutdowns to detect any possibility of ashphaltene coating
(precipitation of ashphaltenes from the HFO caused by dilution with
distillate fuel) which may cause the instruments to read higher than
normal viscosities. If the re-circulation flow is high enough or the
instruments have been supplied with PTFE coating, the ashphaltenes
and any other deposits should quickly be removed by the circulation of
HFO and the expected operating temperatures should be restored.

If not and if the oil quality is known not to have changed, then the
instrument should be removed and cleaned with a rag. Removal should
only be performed in accordance with the engine or burner
manufacturers recommendations or in accordance with safe site practice.
This must include isolation and depressurisation, as detailed below.

15.3 Removal and refitting procedure

Observe safe working practice, wear protective clothing and safety

glasses, and use suitable gloves to prevent burns or absorption of
hot oil.

Check that the isolation valves have been fully closed, remove insulation
and allow to cool to a safe level (cooling will tend to reduce any retained
pressure) and de-pressurise the system if a drain valve or pressure
relieving valve is fitted.

When the above conditions are satisfied - and not before - slacken the
lock nut by 1½to 2 turns, sufficient for the sensor to be rocked. (If
necessary, jolt the ViscoMaster loose with a blow of the hand to the
amplifier housing.) This will allow the seal between the sensor and the
chamber or weldolet to be broken. Do not slacken the lock nut further
unless the seal is broken and the sensor is definitely loose in the fitting.

Note: If the system is still pressurised, the ViscoMaster may lift and
be held against there taining nut. Rocking and alternately pushing
the sensor in and out of the pocket with in the limits allowed by the
slackened nut will break any seal and allow oil under pressure to
seep past the lock nut. If this leakage is excessive, re-tighten the
lock nut and take further action to de-pressurise the system.

When the ViscoMaster can be rocked in the flow chamber and there is no
serious or continuous escape of oil, it is safe to remove the lock nut.

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Always keep all parts of your body away from the axis of the sensor
(i.e., the direction in which the sensor will be withdrawn). If the
system is under pressure or suddenly comes under pressure (e.g.,
due to valve failure or pump start), and the lock nut is not in place,
the instrument may be forcibly ejected from the flow chamber and
cause serious injury.

Clean and maintain the ViscoMaster and then refit it.

15.4 Surge protection

Careful consideration should be given to the likelihood of power supply

surges or lightning strikes. The power supply connections within the
ViscoMaster have a surge arrestor fitted to offer protection against power
supply transients and, to some extent, indirect lightning strikes .If there is
a possibility of lightning strikes, external surge protection devices - one
for each pair of signals and the power supply - should be installed as
close to the ViscoMaster as possible. Another method is to connect an
MOV (Metal Oxide Varistor) (breakdown voltage >30V) with an NE-2
neon bulb in parallel across each wire and ground. These can be
mounted in a junction box close to the ViscoMaster. Further protection
may be offered by the use of an independently powered, fully isolated
RS485 to RS232 converter, which is essential whenever the Modbus
output is permanently connected to a PC.

15.5 ADView

AView is a software package provided by Solartron Mobrey. It enables

you to configure the density and viscosity transmitters and view and save
data from them, to check that they are functioning correctly. ADView is
installed on a PC, and interacts with the transmitter via one of the PC’s
serial (RS232) ports.

ADView requires Microsoft’s Windows operating system: Windows 3.1,

95, 98 or NT.To connect to an RS485/Modbus device, such as the
ViscoMaster, you will need an adapter between the PC and the
transmitter.

ADView provides
• Setting up serial link to communicate with ViscoMaster
• Configuring the transmitter
• Displaying data in real time, or as a graph
• Logging data to a file
• Verifying correct operation of the system, and diagnosing
faults
• Loading or storing Modbus register values
• Read/write to individual Modbus registers.

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15.6 Maintenance

The ViscoMaster is rugged and robust, and has no moving parts. When
correctly installed and operated, servicing is not normally required, even
with poor quality fuel, and no periodic maintenance procedure is
specified. It is recommended that a visual inspection is carried out at
intervals to check for leaks and physical damage, and corrective
maintenance carried out when required.

ADView’s Data Logging facility can be used whenever necessary to

verify that the transmitter is functioning correctly.

Check calibrations should be carried out at specified intervals in order to

identify a malfunction or a deterioration in transmitter performance. If a
fault or a drop in performance is detected, further tests are required to
identify the cause of the fault. Remedial action is limited to cleaning the
transducer tines, making good any poor connections, and replacing the
internal electronics. In the extreme cases the complete transducer may
need to be replaced.

Note: The electronics within the ViscoMaster contain calibration

information relevant to that particular transmitter only. The
circuit boards operate as a pair, and therefore both boards
must be changed together.

Care is essential in handling of the transducer during its

removal from and fitment to the pipeline/tank and during
transportation. Wherever possible, retain and use the
original packaging.

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15.6.1 General inspection and maintenance

No periodic maintenance procedure is specified, but the following

procedure is recommended for periodic inspection. It can also be used
when fault finding

PHYSICAL CHECKS

1. Examine the transmitter, its electronics

housing and cables for any signs of
damageand corrosion
2. Make sure that the spigot connection is tight.
3. Check the transmitter for sign of leakage.
4. Check that there is no ingress of water/fluid
into the electronics housing.
5. Ensure that the threads on the covers are well
greased (graphite grease) and that the ‘O’
rings are in good condition.

The covers MUST be completely screwed down and, in the

case of an explosion-proof enclosure application, DO NOT
FAIL to tighten the locking screws.

ELECTRICAL CHECK

Check the power supply and current consumption at the

transmitter terminals, pins 1 and 2.
These should give:35mA to 42mA at 22.8V to 25.2V.

PERFORMANCE CHECK

When several systems are run in parallel and use the same
fuel source, comparison of the line viscosity, base density
and temperature readings between installations can be a
useful indicator of possible system faults. Differences
between readings, or changes from the normally observed
conditions, should always be investigated to confirm that
instrumentation is functioning correctly.

CALIBRATION CHECK

1. Check calibration.
2. Compare the results obtained with the previous
calibration figures to identify any substantial
deterioration in transducer performance or any
malfunction.
NOTE: A drop in transducer performance is likely due to a build up
of deposition on the tines which can be removed by the
application of a suitable solvent.

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Malfunctions generally could be the result of

electrical/electronic faults in either the
transducer or the readout equipment. Always
check the read out equipment first before
attention is directed to the transducer.

15.7 Calibration

Each transmitter is issued with its own calibration which is programmed

in to the instrument electronics before it leaves the factory. Under normal
circumstances it should not be necessary to re-calibrate the ViscoMaster
provided it is used in the environment for which it was calibrated
originally. The calibration data is shown on a calibration certificate
supplied with the instrument, an example of which is shown below. The
calibration contains the following:

1. The instrument serial number.

2. Four typical points in the output signal Quality
Factor / Viscosity relationship, across the
transmitter’s operating range. This
relationship is using the general viscosity
equation coefficients, which are also listed.
3. Several sample points from the output
signal/density relationship. These have been
calculated using the general density equation
with the calibrated coefficients listed.
4. Temperature coefficient data, K18 and K19;
this defines the correction which should be
applied to achieve the best density accuracy if
the instrument is operating at product
temperatures other than 20°C.
5. One instrument air (density) data point for
check calibration purposes. The values for all
the V and K coefficients shown on the
calibration certificate are programmed into the
ViscoMaster’s registers, and should not be
altered. If the ViscoMaster is used in an
application dissimilar to the one for which it
was originally calibrated, it may be necessary
to re-calculate the V and K coefficients.

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15.7.1 Ambient air calibration check

An air check is a simple and convenient method to see if any long term
drift or corrosion and deposition on the tines has occurred. Ambient air
check procedure:

1. Isolate and, if necessary, disconnect the

transducer from the pipeline.
2. Clean and dry the wetted parts of the
transducer and leave them open to the
ambientair.
3. Apply power to the instrument and check that
the time period of the instrument agreeswith
the figure shown on the calibration certificate
to within ±100ns. If the ViscoMasteris not at
20°C, compensate for this by adding an offset
of +110ns for every °C above20°C, or by
subtracting an offset of +110ns/°C below
20°C.
4. Refit the transmitter to the pipeline if
serviceable or remove for further servicing.

15.7.2 On-line calibration adjustment

An on-line calibration adjustment may be required if the physical

boundary surrounding the tines is different from the physical boundary
used for the factory calibration ot it the unit has suffered long term drift
or corrosion of the tines.

The ViscoMaster is a very accurate and stable instrument, and will

normally provide goodmeasurements. If it is suspected of giving incorrect
results, you should confirm this bycarefully checking the integrity of the
fluid temperature measurement, and compare thiswith the temperature
measurement given by ViscoMaster. You should also verify theintegrity
of the density check measurement. It is only after you have eliminated
all otherpossible causes of error that you should attempt to make
adjustments to the calibration ofViscoMaster.

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15.7.3 Calibration adjustment - stable liquids:

1. Using ADView, reset the line density offset (register 173) to 0, and
theline density scaling factor (register 174) to 1.
2. Ensure that the system has reached its stable operating temperature.
3. With the ViscoMaster operating at typical process conditions, draw off
a sample of the liquid into a suitable container, and note the
ViscoMaster density reading and the operating temperature
4. Measure the density of the sample under defined laboratory
conditions using a hydrometer or other suitable equipment. Refer this
to the operating conditions at the transducer.
5. Calculate the density offset required to make the ViscoMaster
measurement the same as the measured density of the sample.
6. Using ADView’s Register Read/Write tool, configure the ViscoMaster
with the calculated line density offset (Register 173).

15.7.4 Calibration adjustment - unstable or high vapour pressure

liquids:

A pressure pyknometer and its associated pipework can be coupled to

the pipeline sothat a sample of the product flows through it.

1. Using ADView, reset the line density offset (register 173) to 0, and
the line density scaling factor (register 174) to 1.
2. Ensure that the system has reached its stable operating temperature.
3. When equilibrium conditions of product flow are reached, note the
ViscoMaster density reading and temperature and simultaneously
isolate the pyknometer from the sample flow.
4. Remove the pyknometer for weighing to establish the product
density.
5. Compare the pyknometer reading with the ViscoMaster reading and
compute the density offset required.
6. Using ADView’s Register Read/Write tool, configure theViscoMaster
with the calculated line density offset (Register 173).

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15.8 Trouble shooting

Fault Possible cause Remedy

Readings Analog output averaging time Increase the averaging time using
fluctuate slightly, not long enough ADView’s Board Configuration facility.
i.e., are noisy
Erratic readings One or more of: Remove primary cause; e.g.:
Gas bubbles around tines; - install air release units to release gas;
cavitation; severe vibration or - apply back pressure to discourage
electrical interference; large formation of bubbles;
amount of contaminants - remove cause of vibration Alternatively,
it may be necessary to adjust the Time
Period Trap.
Readings outside Deposition and/or corrosion on Clean tines
limits the tines.
Analog output = No power to analog output If voltage across pins 5 and 6 is not 15 to
0mA 28V, replace power supply.
Analog output circuit failure Use ADView’s facility to set the analog
output to 4, 12 or 20mA (in Board
Configuration) to check whether the
output is functioning. If not, replace
circuit boards.
Analog output is Alarm condition caused by lack If voltage across pins 1 and 2 is not 20 to
2mA of power to ViscoMaster 28V, check and replace main power
supply.
Alarm condition caused by other Use ADView Diagnostics to check that
internal failure phase locked loop is in lock.
Temperature If analog output and Modbus Return the transmitter to Auramarine Ltd
readings appear to be functioning
incorrect correctly, the temperature
sensor has probably failed.
ViscoMaster Power failure to ViscoMaster Check power supply to ViscoMaster and
does not converter; replace if necessary
communicate Power supply to RS485/232 Check wiring
with ADView converter failed.
A and B Modbus connections Check wiring
reversed
RS485/232 converter failed, Try another converter
wired incorrectly, or connected
the wrong way round
ADView incorrectly installed on Re-install ADView
PC
Incorrect Slave address chosen Check slave address
for ViscoMaster
RS232 port on PC failed. Connect to another free RS232 port on
the PC, if available. Alternatively connect
a known working RS232 device to the
PC to check that the port is working.
Viscosity reads HFO quality changed Check oil quality is within spec. Use oil
high during from another tank and contact supplier.
normal running Steam flow reduced Verify steam flow
Flow rate too low Increase flow or change to smaller flow-
through chamber
Insulation defective Repair or replace insulation
Viscosity reads Pump coated with asphaltenes Check pump delivery; service pump.
high after engine Bypass not fully closed Close bypass
shutdown and PTFE laminate damaged, Remove ViscoMaster for visual check;
restart leading to coating of fork tines return to Auramarine Ltd.
Calibration data is corrupted Compare calibration data to certificate or
stored configuration. Reprogram as
necessary. Return to Auramarine Ltd

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16 HEAT EXCHANGER, TYPE S14

16.1 Starting up and running instruction

By starting up and running of the plate heat exchanger the following

points must be observed:

- Working Pressure: On the head of the plate heat exchanger a name

plate is mounted. The maximum working pressure is stated and it
must not be exceeded.
- Pump Start:Pump start has to be done with closed valves always.
After that the maneouvering of the valves must take place slowly in
order to avoid liquid pressure chocks.
- Pressure Pulsations and Vibrations: No pressure pulsations and
vibrations must be transferred from positive pumps or equipment like
that. If these are transferred to the plate heat exchanger fatique
fracture in the plates can arise.
- Leakage during Start Up: Leakage during start up can arise. This
stops when gaskets and plates have obtained running temperature
and when the pressure has equalized in the whole plate heat
exchanger.
- Airing: Air in the plate heat exchanger reduces the heat transmission
and increases the pressure drop. Therefore the plate heat exchanger
has to be aired.
- Pressure Rise and Change of Temperature: During running the
pressure and the temperature have to be controlled frequently. A
rising pressure drop and a falling heat transmission indicate that
some scalling has deposited on the plates. The scalling has to be
removed, see page 10 concerning cleaning the plate heat exchanger.
- Leakage during Running: See paragraph fault location.
- Longer Working Pauses: A plate heat exchanger, which is out of
work for a longer period, ought to be emptied and cleaned. After
emptying and cleaning the plate heat exchanger is tightened gently
and covered with black plastic to prevent the gaskets from being
damaged by daylight. Before the plate heat exchanger is put to work
again it must be tightened according to minimum measure. See
paragraph Mounting and Assembling.

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16.2 Opening and assembling

By opening and assembling the plate heat exchanger the following things
have to be observed:

- Without Pressure and Cooled

Before opening the plate heat exchanger be sure that there is no
pressure in it and that the temperature is cooled down to 35°C. If the
plate heat exchanger is opened at a temperature higher than 35°C,
the gaskets can get loose from the plates.

- Opening and Dismounting

By opening the plate heat exchanger the bolts have to be loosened
equally. (I.e. that the follower shall have a straight moving by
opening). The last distance of the opening can be made by 2 bolts.
After that, the follower is pulled back towards the column. If the plate
heat exchanger is installed onboard a ship the follower has to be
fastened to the column.

- Mounting and Assembling

The plates and the gaskets are checked carefully before mounting -
the plates have to be clean and the gaskets have to be without fatty
substance and other uncleanness. A grain or sand on the gasket can
cause leakness during running and damage of gaskets.
The plates are being mounted according to the diagram -the gaskets
always have to be turned towards the head of the plate heat
exchanger. If the gaskets have been changed or the plate heat
exchanger has just been delivered the plate heat exchanger is
assembled according to the minimum measure stated on the name
plate and the enclosed drawings + 0.1 mm per plate.
During the assembling the head and the follower have to be parallel.
It is therefore necessary to measure the assembling on the top and
the bottom on both sides.

16.3 Cleaning

Both capacity and corrosion resistance of the plate heat exchanger are
depending on the cleaning of the plate heat exchanger.
-manual cleaning
-cip cleaning
-cleaning materials
-control of cleaning

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16.3.1 Manual Cleaning

The plate heat exchanger is separated and the plates are pulled from
each other. Use a soft brush and a qualified cleaning material for
cleaning the plates.
If the cover is thick, from scale or organic material the plates are put in a
vat with a qualified cleaning material.

NOTE: Wire brush, sandpaper, metalscraper etc. must not be used.

Neither the plates nor the gaskets can bear heavy-handed /
robust treatments. A high-pressure-cleaner can be used but
with absolute care, and never add abrasives.

16.3.2 CIP Cleaning

To use CIP cleaning (cleaning in place) it is a condition that the scalling

on the plates is soluble. All materials in the whole circulation system of
course have to be
resistant to the cleaning material.
The cleaning can be done without circulation, too. This is done by filling
up the plate heat exchanger with a qualified cleaning material. After
some time the cleaning material is washed out with clean water.

Examples of CIP cleaning:

-product rests and cooling/heating liquids are drawn off
-rinse with cold or tepid water
-warm cleaning fluid circulates
-rinse with cold or tepid water
-rinse with water added a chemical
-rinse with cold or tepid water

16.3.3 Cleaning Materials

A qualified cleaning material can shortly be defined as scalling on the

plates is being removed without damaging plates and gaskets.
Stainless steel has a passivated (protecting) film. This film must not be
destroyed, as the film assists in preserving the resistance of the stainless
steel.

Oil and grease is removed with a water emulsifying oil solvent i.e. BP
system cleaner.
Organic and grease cover is removed with sodium hydroxide (NaOH)
maximum concentration 1.5% -max. temp. 85°C. Concentration = 5.00
Itr. 30% NaOH per 100 Itr. water.

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Stone -and limestone is removed with nitric acid (HNO) -max

concentration 1.5% -max. temp. 65°C. 1.5% concentration = 2.4 Itr. 62%
(HNO) per 100 Itr. water.
Nitric acid also has an effective build up effect on the passivation film of
stainless steel!

Cleaning is an important part, influencing on the effectiveness of the

plate heat exchanger. Therefore the plate heat exchanger has to be
separated for inspection -and especially in the commissioning period.
You will obtain important experience concerning circulation times,
temperatures, and chemical concentrations.

Reasons for unsufficient cleaning often have to be looked for among the
following:
-too low circulation quantity
-too short cleaning period
-too low chemical consumption compared to the scalling of
the plates
-too long running intervals between the cleanings

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16.4 Fault location

- reduced capacity
- external leakage
- inside leakage

16.4.1 Reduced Capacity

If a reduction of the heat transmission and/or a rising pressure drop is

maintained, the plate heat exchanger has to be cleaned.

16.4.2 External Leakage

- Maybe the plate heat exchanger is running with a higher working

pressure than mentioned on the name plate. In that case the
pressure has to be controlled and if too high it has to be reduced
immediately to what is written on the name plate.
- Tighten the plate heat exchanger to the minimum measure which is
mentioned on the name plate. It goes without saying that the plate
heat exchanger has to be pressureless before tightning.
- The plate heat exchanger is separated for inspection. Check that the
plates are without scalling and undeformed.
- Check the gaskets. They have to be elastic, undetormed and to have
a clean surface. All gaskets and plates are cleaned carefully -even a
grain of sand on the gasket surface can cause a leak.

A plate stack, assembled to a minimum measure after cleaning, has to

be tight. If a leakage is still present the gaskets normally have to be
changed. If there is a leakage through the drain holes of the gaskets the
reason can be a defective gasket in the drained zone or a corroded plate
in the drained zone.

16.4.3 Inside Leakage

If the liquid is mixed it is due to holes in one or more plates. The leaks
can only be repaired by changing the defective plates.

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A suspected leakage can be located in one of the following ways:

- Remove a pipe on one of the buttom pipe connections -then put the
opposite side under pressure. After the pressure is stabilized the
liquid must not run off from the removed pipe connection. If the liquid
continues to run off there is a leak on one or more plates. The plate
stack is demounted and every single plate is examined carefully.
- The plate heat exchanger is separated and all the plates are dryed.
After drying the plates are put into the plate heat exchanger and
assembled. Now the liquid is circulated with full capacity but only on
one side (every second plate interval). The other half of the plate
interval is kept without pressure and without liquid. The circulation is
stopped after a few minutes and the plate heat exchanger is opened
carefully so that no water is sprayed on the dry plate side. The plates
are examined carefully and thus it is possible to find the wet areas on
the dry plates. The areas have to be controlled with capillary liquid.
- The plate heat exchanger is separated and all plates are controlled
with the capillary liquid.

16.5 Reassembly

The plate heat exchanger is module built up and therefore flexible as

regards enlargements or reductions. I.e. it is easy to change the capacity
by respectively enlarging or reducing the number of plates.

16.6 Spare parts

The type designation of the plate heat exchanger and the manufacture
number (on the name plate which is placed on the head cover) ought to
be mentioned when ordering spare parts. This is to prevent fault delivery.

- by ordering plates it is important to mention the right pattern code and if

it is right or left plates.

- by ordering a complete set of gaskets and the glue for these and the
cleaning fluid it is enough to mention the manufacture number or the
number of the drawing.

- when ordering single gaskets it is important to mention the correct

quality. The quality appears from the diagram and the colour marks on
the gasket.

- when ordering assembling bolts it is necessary to measure the old

assembling bolts to secure the delivery of the right size of bolts.

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17 HEAT EXCHANGER TYPE MX

17.1 General Description

Vesta MX heat exchangers are of the shell and tube type with u-bend
tubes. All heaters have been hydrostatic pressure tested before delivery.
Vesta MX heat exchangers have been type approved by all major
classification societies.

17.2 Operation

17.2.1 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.

17.2.2 Initial start-up

Fluid flow through the heat exchanger must be established before

the heating medium is applied.

Operate the heater for one hour, stop, and retighten all screws.

17.2.3 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 according to heater size calculation. The output is
furthermore subject to correct type of steam trap being used. Correct
layout of the condensate system avoids negative effect of counter
pressure.

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17.2.4 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.

17.3 Maintenance and cleaning

During disassembly, inspection, reassembly and testing it is

important that all safety measures are observed.

The fluids in the systems can be both hot and flammable. Therefore
it is important during disassembly and cleaning that proper
depressurising, isolation and draining is performed, as well as
spillage control. The mandatory pressure test is to be carried out
with great care.

Insulation and splash guards must be fitted during

recommissioning.

17.3.1 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.

17.3.2 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.

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17.3.3 Heavy contamination

If the heater is heavily contaminated with carbon deposits, the

manufacturer recommends the heater chemically cleaned with a carbon
remover.

After the cleaning has been completed, the heater must be flushed
carefully with fresh water and allowed to dry afterwards.

17.3.4 Checking the safety valves

Once every year the safety valve must be checked for correct setpoint.

17.3.5 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

dismantling 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.

NOTE: Fluid flow through the heat exchanger must be established

before 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 the table
below.

NOTE: A pressure test should be carried out to prove tight joints.

Heater 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
Heater main flange bolts tightening schedule (dry values) – T16 types

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17.4 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 Auramarine Ltd.

4 Flange gaskets
5 Tube insert
6 In and outlet flange gaskets
7 Steam and condens flange gaskets

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18 SCREW PUMP, TYPE ACE3 WITH MAGNETIC COUPLING

Oil leakage may make the floor slippery and cause personal injury.
Failure to comply with these instrutions may cause damage and
personal injury!

When handling liquids that may harm skin use gloves and/or
protective clothing.

When handling liquids which may involve fire hazards appropriate

precautions to avoid danger are to be taken.

Starting a dry pump is likely to cause damage to the pump and it's
bearing and magnetic coupling.

If operating temperature exceeds 60°C (149°F), appropriate

measures to avoid skin contact shall be provided.

Use hearing protections whenever high noise can be expected from

pump, motor and/or environment.

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18.1 Start-up

18.1.1 Before starting

After installation and whenever it can be assumed

that the pump has been emptied, the pump must be
thoroughly filled with liquid (see fig.).

Make sure the prime mover is locked out and can not be started
accidentally.

Rotate the shaft by hand while filling the pump, to ensure that the rotor
bores and magnetic couplings are filled. This is done by rotating the fan
on the electric motor after removing the fan cover.

Do not forget to fit the motor fan cover again before making start of
motor possible.

If the suction pipe cannot be completely filled, it is important

o ensure that the trapped air is evacuated without any
pressure build up (see fig.).

Starting a dry pump is likely to cause damage to the pump and it's
bearing and magnetic coupling.

18.1.1.1 Direction of rotation

When the pump is ready to be started, switch the motor briefly on and off
and check that the drive motor rotates in the correct direction as
indicated by the rotation arrow. The arrow is placed on different spots
depending on the pump series.

Don't mix up with arrow for inlet and outlet!

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18.1.2 Starting

Check that all valves necessary for the operation are fully opened in both
discharge and suction lines. The first time, the pump should be started
with the adjusting spindle of the pressure relief valve tightened to half of
the available turns (the valve setting is increased when the spindle is
turned clockwise).

By monitoring the pressure gauge it can be determined when the suction

line is primed and the pump begins to work. Should the pump not operate
normally soon after start, stop the pump within half a minute. Start again
after about 3-5 minutes and run for half a minute. This procedure may
need to be repeated a couple of times if the suction line is long. Should
the pump still not work, it must be assumed there is a problem in the
system that needs to be remedied, see ”Trouble shooting”.

18.1.2.1 Setting the pressure relief valve

The setting of the opening pressure is made as follows:

Tighten the valve spindle by rotating clockwise to the maximum extent.
The system pressure is regulated by throttling to required value. The
pressure relief valve is eased until the pressure is just beginning to
decrease by turning the spindle CCW. The valve is now preset for
desired opening pressure. Open the throttling valve entirely.

If operating temperature exceeds 60°C (149°F), appropriate

measures to avoid skin contact shall be provided.

Use hearing protections whenever high noise can be expected from

pump, motor and/or environment.

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18.2 Maintenance

The intervals for inspection and replacement of wear parts vary greatly
with the properties of the pumped liquid and can only be determined by
experience.
Pumping liquid which contains abrasive materials, or liquid that is
corrosive, will significantly reduce service life and call for shorter service
intervals.
Wear will normally show as unnormal:
• Vibration
• Noise
• Loss of capacity
• Reduction in flow/pressure

If the pumps operating temperature exceeds 60°C let the pump cool
off before any service, maintenance or dismantling work is
commenced to avoid burn injury.

For maintenance the following spare part sets are recommended:

G054 Major kit: For repair after damage or greater wear.

G057 Joint kit: For dismantling the pump.

Ordering example: For IMO-pump ACE 032N3 NKBP, serial number

456789:
Ball bearing pos 122 p/n 173765 Valve element pos G070 p/n 189873

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18.2.1 Inspection of rotors

A quick inspection of the idler rotors can be made simply by removing the
rear cover. Note that the driver must be deenergized and the pump
hydraulically isolated before the rear cover is removed.

If a more thorough investigation is needed, proceed as under

”Dismantling” and ”Reassembly”.

Useful tools

A = Puller
B = Screw spanner 16 mm
C = Plástic mallet
D = Alien keys (3 mm & 5 mm}
E = Mounting sleeve, D=25,5 mm
F = Screw driver
G = Plier
H = Guide pins
I = Oil can

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18.2.2 Magnetic coupling

M = Screws (006A)
N = Drivehub(998)
O = Screw (998B)
P = Washer (998A)
Q = Outer magnetic rotor
R = Can screws
S = Sealing can
T = Retaining ring
U = Inner magnetic rotor
V = O-ring (007B) W = Cover (520) Y = O-ring (520A)

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18.2.3 Dismantling

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18.2.4 Reassembly

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18.3 Trouble shooting

Problem Cause Action

Wrong direction of Electric cables to motor wrongly Reverse the terminal connection
rotation connected. on electric motor.

Connecting and discon-necting

of electric cables must be done
only by personnel authorized to
do such work.
The pump cannot be Wrong direction of rotation. See above.
primed Suction line is not open or Check all components in suction
pressure drop in the suction line line. The inlet condition should be
is too high checked with a vacuum gauge at
the pump inlet.
Check oil viscosity.
Major air leakage into the suction Check the suction line.
line
The pump cannot evacuate the In installations with negative
air through the discharge line due suction head, where the pump
to excessive counter pressure. might be started against a
pressurized system, a deaeration
pipe with an orifice (2-3 mm
recommended) has to be installed.
The deaeration pipe should be
connected to the outlet pipe’s
highest point.
This must also be installed
when the pump is used as an
stand-by pump.
No flow The pump is not primed. See above.
The pressure relief valve is set Check outlet line. Readjust the
below the counter pressure or pressure relief valve to a value
outlet is blocked. above counter pressure.
Flow too low The pressure relief valve is set Readjust the pressure relief
too low (Discharge pressure also valve
low).
Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
The pumped liquid contains a See Noise and Vibration
significant amount of
compressible gas, such as free
air. (This would usually cause
noise).
Pressure too low The pressure relief valve is set Readjust the pressure relief
too low valve.

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Counter pressure in the Check the components in the

discharge line is too low due to a discharge line inclusive the
major leakage. recipients.
The valve piston is stuck in open Check the valve. See
position. Installation & Service
instruction for respective pump.
Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
The pumped liquid contains a See Noise and Vibration
significant amount of
compressible gas, such as free
air. (This would usually cause
noise).
A too small pump has been Contact Auramarine Ltd
chosen
Pressure too high The pressure relief valve is set Readjust the pressure relief
too high. valve.
The oil is too cold (or has higher Reduce the pressure setting until
viscosity than anticipated operational
temperature has been reached.
Counter pressure in the Check the discharge line.
discharge line is too high.
Drive motor difficult to Counter pressure too high. See above: Pressure too high.
start or tends to stop Liquid too cold. Readjust the pressure relief valve
by tripping the motor to a lower value. Thus the power
overload relay consumption for the pumping is
relieved and overloading due to
the high viscosity may be avoided.
When the liquid has reached
normal temperature and thus
flows easily, the relief valve is
reset to normal pressure
Motor is undersized for the Check the motor
prevailing conditions.
Electrical power supply faulty. Check the motor and motor
connection
Motor overload relay set too low Readjust or replace the relay
or is faulty.
Incorrect setting of Y/D starter. Readjust the setting of the starting
sequence.
The time before the motor
overload relay is tripped should
not exceed 10-15 seconds.

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Noise and vibration The flow to the pump is See Flow too low
insufficient.
Monitor the pump Insufficient support of pipe work Check for pipe vibrations in the
function and shut pump connections. Check that
down if any sign of the pipes are sufficiently
malfunction is noticed clamped.
Air leakage into the suction line Check the suction line for air
leakage.
Free air in the liquid or gas Contact Auramarine Ltd
cavitation
Faulty electrical supply. Check all three phases of the
supply.

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18.4 Components
Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: L3/K3/N3
With version codes: { N { K { B { P The version code is composed of the letters in the 4 columns.
{L Example of pump designations std: ACE 025L3 NKBP
{M

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18.4.1 Spare parts

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19 AC ELECTRIC INDUCTION MOTORS

19.1 Maintenance

Induction motors require very little maintenance. A regular regime of

inspection is recommended to ensure minor problems do not escalate to
break downs. Typical intervals would be 2000 hours of operation or 3
months, whichever is sooner.

Checklist:

- No visible damage ie fans cracked, fan cowlsbent, foot cracked etc

- No accumulation of dust or fibres on the frame or around the fan inlet
- No significant corrosion of the lifting lugs/eyebolts
- No excessive vibration
- No loose fasteners
- Cables and earths are sound
- Sealing of the motor and gland plate in good condition
- Insulation resistance adequate, imperative this is checked after a
prolonged shut-down

NOTE: Fumex smoke extraction motors should be rewound after

5 years of operation.
Regrease required, particularly large output 2 pole motors.
Bearing condition.

19.1.1 Periodic maintenance

- Remove the cover and the fan which is keyed, clamped, pinned or
knurl located to the shaft extension.
- Loosen and remove bearing cover screws and end shield bolts/studs.
The end shields should then be eased off their spigots. The rotor can
now be carefully withdrawn from the stator, taking care not to
damage the stator bore and both stator and rotor windings.

Having dismantled the motor, maintenance can be carried out to remove

all dirt. For this purpose, the use of an air line supplying dry compressed
air under comparatively low pressure is best, as a high velocity air-
stream can force dirt into the spaces between the windings and
insulation, etc.

Grease-removing solvents should only be used very sparingly to avoid

damage to impregnating varnish or insulation.

Motors should be re-assembled in the reverse order from dismantling,

remembering to ease end shields onto bearings and spigots. Do not use
force.

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Before starting, check that the rotor revolves freely. Ensure that the
electrical connections are correct and terminal nuts tight.

19.1.2 Wound rotor

Brushes should be inspected every 1000 running hours or at three

monthly intervals if this is a shorter period of time. The inspection should
include checks for brush wear and tensioning.

Built up of carbon dust should be removed using a suitable dust

extraction unit.
Replacement of brushes is recommended when the brush is
approximately a quarter of the way down the brush holder. On calliper
type designs the brushes should be replaced when1/4” (5mm) of brush
remains .It is important that the correct grade of brush is being used as
this significantly affects operation.

19.1.3 Hazardous area motors

In addition to the conditions referred to, special requirements apply to

motor types Ex N, Ex nA, EEx e, EEx d, EEx de. Refer to the approval
certificate and appropriate codes of practice eg BS 5435.

19.2 Replacing non-drive end bearing

This instruction relates to W-DA100 - W-DA180 frames fitted with internal

circlip.

19.2.1 Bearing removal

1. remove fan cover and fan.

2. remove Non-Drive End shield fixing bolts and withdraw Non-Drive
End shield with rotor assembly from stator.
3. remove Non-Drive End oil seal levering with a screw driver.
4. remove bearing retaining external circlip from the shaft.
5. press shaft through and out of the bearing inner race, leaving the
bearing inside the end shield.
6. experience shows that the bearing housing and circlip will not be
damaged.
7. using reverse action circlip pliers, remove internal circlip from
bearing housing.
8. bearing can easily be removed using hand tools bearing can easily
be removed using hand tools.

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19.2.2 Bearing replacement

1. place end shield on flat surface with inside facing upwards and
insert the replacement bearing.
2. fit internal circlip. Note that the bevel on the circlip must be away
from the bearing.
3. heat new end shield bearing assembly using bearing induction
heater or hotplate type bearing heater.
4. push/press the end shield/bearing assembly onto the shaft, using
the bearing inner race as an abutment, until the bearing is located
against the shaft shoulder
5. allow to cool.
6. refit external circlip to secure bearing.
7. fit new oil seal with its open side facing outwards. Take care not to
damage the oil seal lip.
8. reassemble motor.

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19.3 Spare parts

Aluminium construction Frame sizes DA63, W-DA71 to W-DA180*

1 Aluminium flange endshield, frames 16 Non-drive end oil seal

100-132, cast iron flange frames 160-
180
2 Endshield fixing bolt 17 Fan
3 Drive end endshield 18 Fan circlip
4 Rotor assembly 19 Fan cover
5 Flinger 20 Fan cover screw and washer
6 Drive end oil seal 21 Foot fixing bolts and washer
7 Preload washer 22 Detachable feet
8 Drive end bearing 23 Terminal board
9 Stator assembly with or without feet 24 Terminal box to frame gasket
10 Eyebolt (when fitted) 25 Terminal box
11 Bearing retention circlip 26 Internal earth terminal
12 Non-drive end bearing 27 Terminal box lid gasket
13 Non-drive end endshield 28 Terminal box lid
14 Endshield fixing bolt 29 Pad mounting bracket
15 Bearing circlip 30 Face endshield
This drawing typifies the range W-DA100ÐW-DA180

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Steel construction, frame sizes 7-DS225 to 7-DS355

1 Drive end outer bearing cap 18 Fan circlip (replaced by shaft shoulder
on some sizes)
2 Drive end oil seal (Labyrinth seals on 19 Non-drive end outer bearing cap
Energy Efficient motors)
3 Drive end endshield (foot mounted) 20 Tolerance ring
4 Grease nipple 21 Fan circlip
5 Nameplate 22 Fan cover, for low noise option
6 Drive end bearing 22A Fan cover
7 Drive end inner bearing cap 23 Flange endshield
8 Rotor assembly 24 Terminal box lid
9 Stator frame with feet 25 Terminal box gasket
10 Bi-directional internal fan 26 Terminal board
10A Bi-directional external fan, for low noise 27 Terminal box
option
10B Bi-directional external fan 28 Detachable gland plate (frame sizes
225-250)
11 Fan circlip 29 Angled cable entry (frame sizes 280-
355)
12 Non-drive end inner bearing cap 30 External earth terminal
13 Non-drive end bearing 31 Thermistor connection block
14 Non-drive end bearing circlip 32 Adaptor for skirt mounting
15 Non-drive end endshield
16 Grease nipple and extension pipe
17 Non-drive end oil seal (Labyrinth seals
on Energy Efficient motors)

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Cast iron construction, frame sizes DF80 to DF100

1 Drive end endshield 15 Non-drive end inner bearing cap screws

2 Endshield fixing bolts 16 Fan cover
3 Stator assembly with or without feet 17 Terminal box lid
4 Pack peg 18 Terminal box lid screws
5 Drive end oil seal (when fitted) 19 Internal earth terminal
6 Preload washer 20 Terminal box lid gasket
7 Drive end bearing 21 Terminal box
8 Rotor assembly 21A Terminal box fixing screws
9 Non-drive end inner bearing cap 22 Terminal box to frame gasket
10 Non-drive end bearing 23 Terminal board
11 Non-drive end oil seal (when fitted) 24 Flange endshield
12 Non-drive end endshield 25 Face endshield
13 Fan cover screws and washer 26 Bearing circlip
14 Fan 27 Fan locating pin

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20 LIMIT SWITCH TYPE PCR

Pos. Pcs. Description Material

1 1 Housing (base) Vestamid
2 1 O-ring –sealing NBR/EPDM
3 1 Housing (cover) optional
4 1 TCR-axis PDM
5a 1 Switch cam system adjustable PDM, A2
6 2 Mircoswitch -
7 1 Bracket, size 1-4 A2

The Microswitch-box converts the mechanical end or middle position of

the actuator into electrical signals. The microswitch in the body is
commonly used where there are no special requirements or the working
voltage should be set free.

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The microswitch with its compact design is very suitable for mounting into
the housing. When used as a potential free contact, the switch provides a
very wide range of controlling possibilities.

The fully adjustable serrated cams are locked together to ensure that the
adjusted setting is secured against any vibration.

20.1 Wiring Diagram

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21 BALL VALVES, TYPES N2, N8 AND N9

21.1 Operation

During operation the ball valves must be in either complete OPEN

or CLOSED position in order to ensure their smooth and efficient
working and long duration of seats. Leaving the ball in half open
position could eventually cause damage to the soft seats.

21.1.1 Manual operation

The opening and closing of the valve is done by turning the handle a
quarter turn (90°)
a.) valve is in open position when the handle is in line with the valve and
pipe line
b.) valve is in closed position when the handle is across the pipe line

21.1.2 Automated operation

Valve can be automatically operated by: A pneumatic actuators (DA or

SR), B hydraulic actuators, C electrical actuators, D gear box (manually
operated). In this case no stop is fitted on the valve since it is normally a
part of the actuator.

21.2 Maintenance

Before starting the maintenance, be sure that all pressure on the

pipe is relieved.

Open and close the ball valve at least once to release the pressure
completely also from the valve body.

- the ball valves if correctly used, normally do not need any internal
lubrication and maintenance. However, when necessary, ball , or
seats can be replaced
- only by relatively qualified personnel following the instruction of the
manual without needs to use any machinery
- for further information about the recommended spare parts please
check drawing and contact Auramarine Ltd.

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21.2.1 Steam leakage

If leakage is evident on stem packing area, it can be eliminated by

increasing the tightness of the lock nut 2B. In case leakage is still
persisting the replacement of the stem packing 3 is recommended. For
handle nut and lock nut (2A-2B) tightness see table.

21.2.2 Body seals leakage

Check for the tightness of the body bolts 16 according to table in case it
is still leaking, it is necessary to replace the body seals 11-18.

21.2.3 In line or seats leakage

Check that valve is in fully closed position if so and the leakage is

persisting the valve must be disassembled to replace damaged parts.

Safety precaution before removing the ball valve line for

disassembly

a.) check that all pressure is exhausted from the line (upstream and
downstream) and half open the ball to ensure that no pressure is
trapped in the body cavity. In other words it must be drained of
all fluid/gas and pressure.
b.) remove the valve from the line and cycle valve at minimum 1 full
cycle to ensure that any pressure trapped is released.
c.) If the fluid in the line and into the valve is toxic, inflammable,
corrosive or damaging for any other reason, it is advisable to
take following precaution during the valve repairing:

- use protective eye mask or glasses

- use gloves, overalls and suitable footwear
- ensure that running water and fire extinguisher is
easily available at any moment

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21.3 Valve disassembly to inspect and/or replace body seals, seats,

packing and ball

a.) set the valve in open position and take out all body bolts 16 and
complete body from end connections
b.) close the ball and remove seats10, ball 9 and body seals 11-18, be
careful not to damage the ball
c.) remove handle nut A2, name plate, handle 1, stop washer 17, lock
nut 2B, spring washer 4, gland packing 6
d.) push the stem 5 into the body 12. Remove packing rings 7 from body
and O’ring 8 plus thrust washer 7 from stem.

21.4 Inspection and replacement

With the valve completely disassembled, clean and examine all the
following components:

a.) surface of the ball: any surface defect, particularly in the seating area
will be extremely detrimental to the performance of the valve and
therefore the ball should be replaced if found defective.
b.) seats: replacement or seats is recommended
c.) stem seals and body seals: also to be discarded and replaced by a
new one
d.) remaining components of the valve: after cleaning it is required a
careful examination for wear, corrosion and mechanical damages
particularly on threaded components. If components are found
defective they should be replaced.

21.5 Re-assembly

Clean inside of body and stem housing. A light oil/grease compatible with
line fluid can be used on ball, seats and stem surfaces.

21.5.1 Steam re-assembly

a.) replace thrust washer and O’ring 7-8 and then insert the stem from
the inside body
b.) install the packing ring 3, gland packing 6, spring washer4 and lock
nut 2B and tighten. To avoid rotation of stem, apply temporarily the
handle.
c.) install stop washer 17, handle 1, name plate, handle nut 2A and
tighten (see values given in the table)

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21.5.2 Ball, seats and seals re-assembly, types N8 and N9

a.) insert the fourth seat into the body and then insert the ball
b.) insert the seat-retainer 23 together with the seat 10 and retainer-seal
18 and then repeat the operations on the opposite way. ONLY NOW
you can assemble the n. 2 end-caps and tighten.
c.) repeat the operations on the third way (third and fourth in case of 4
ways).

21.5.3 Ball, seats and seals re-assembly, type N2

a) place the stem in closed position and insert the ball in the same
position
b) rotated in open position and then insert the seats and body seals
c) insert the center-piece between the end-caps and tighten bolts and
nuts firmly (see values given in table)

21.6 Testing

a.) after having completed the re-assembly check for the

manoeuvrability of the valve and make sure that ball rotates freely
b.) if facilities are available, test the ball valve to the appropriate
specification

21.7 Automated ball valves

a.) if the valve is automated, reinstall the actuator and please note that
the handle is not used. If necessary, reset the stops. First set- the
valve in open position and check that ball is fully open. Second set-
the valve in closed position and check, adjusting if necessary, for the
best closure.

b.) CAUTION! Valves with electrical actuators should be tested

starting from valve in: HALF OPEN - HALF CLOSED POSITION.
This is to ensure that electrical connection is all right and
rotation is correct. In case of wrong position switch off
electrical actuator immediately and change the direction. Limit
and torque switches are ineffective if rotation is wrong.

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21.8 Tightness values for handle nut 2A-2B and body bolts 16, types
N8 and N9
VALVE SIZE HANDLE NUT 2 A BODY BOLTS PART NO.
LOCK NUT 2 B 16
FULL RED DIMENSION NM INCH DIMENSIO NM INCH
BORE BORE LBS N LBS
¼ ⁄ M 10X1 8 70 M8X17 35 310
3/8 ½ M 10X1 8 70 M8X17 35 310
½ ¾ M 10X1 8 70 M8X17 35 310
¾ 1 M 12X1.25 15 130 M10X22 50 440
1 1¼ M 12X1.25 15 130 M10X22 50 440
1¼ 1½ M15X1.5 25 220 M12X30 70 620
1½ 2 M15X1.5 25 220 M12X30 70 620
2 2½ M15X1.5 25 220 M12X30 70 620
2½ 3 M22X1.5 40 355 M12X35 70 620
3 4 M24X2 50 440 M12X35 70 620

21.9 Tightness values for handle nut 2A-2B and body bolts 16, type N2
VALVE SIZE HANDLE NUT 2 A BODY BOLTS PART NO.
LOCK NUT 2 B 16
AND NUTS PART NO 19
FULL RED DIMENSION NM INCH DIMENSIO NM INCH
BORE BORE LBS N LBS
¼ ⁄ M 10X1 8 70 M8X47 35 310
3/8 ½ M 10X1 8 70 M8X47 35 310
½ ¾ M 10X1 8 70 M8X51 35 310
¾ 1 M 12X1.25 15 130 M10X64 50 440
1 1¼ M 12X1.25 15 130 M10X75 50 440
1¼ 1½ M15X1.5 25 220 M12X88 70 620
1½ 2 M15X1.5 25 220 M12X95 70 620

21.10 Storage

Valves to be stored for a long time shall be checked by the quality control
personnel every 6 months; every 3 months when valves are actuated.

Maintenance during storage period:

a.) internal surface must be inspected to check complete dust or other

foreign parts absence
b.) old rust or any dust must be removed by wiping with proper solvent
c.) after cleaning, ball valves must be lubricated by using an adequate
lubricant
d.) ball valves must be operated for a least 2 complete cycles

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21.11 Spare parts

N8 and N9
Item NO Q.TY PART NAME
1 1 Handle
**2ª 1 Handle nut
**2b 1 Lock nut
*3 1 Packing ring
**4 2 Spring washer
**5 1 Antistatic stem
6 1 Gland packing
*7 1 Thrust washer
*8 1 O-ring stem
**9 1 Ball
*10 4 Seats
*11 3-4 Body seal
12 1 Body
13 3-4 End connections
14 1 Stop-pin
16 16-20 Bolts
**17 1 Stop washer
*18 3-4 Retainer seal
23 3-4 Seat retainer

N2
Item NO Q.TY PART NAME
1 1 Handle
**2ª 2 Nut
*3 1 Packing ring
**4 2 Spring washer
**5 1 Antistatic stem
6 1 Gland packing
*7 1 Thrust washer
*8 1 O-ring stem
**9 1 Ball
*10 2 Seats
*11 2 Body seal
12 1 Body
13 2 End connections
14 1 Stop-pin
16 4 Bolts
**17 1 Stop washer
*18 2 Body seal
19 4 Nuts

* suggested materials after 2 years service

** suggested materials after 5 years service

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22 PRESSURE LIMITING VALVE SPVF

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.

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

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22.1 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
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.

22.2 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

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22.3 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.

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.

22.4 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.

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23 VALVE, SERIES 776000

1 Body
2 End connection
3 Ball
4 Ball seats
5 Rings
6 Thrust washer
7 Ring
8 Stem seat
9 Packing gland
10 End stop
11 Spring washer
12 Nut
13 Stem
14 Handle

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24 SWITCHBOX, SERIES W AUTOMAX

24.1 Adjusting limit switches

Disconnect power before removing the cover!

Make the actuator/valve system rotate CW, then adjust as

follows Pull the BOTTOM cam to disengage it from
splines, then rotate it CW just until switch trips. Reengage
the cam with splines.
Make the actuator/valve system rotate CCW.
Push the TOP cam to disengage it from splines, then
rotate it CCW just until switch trips. Reengage the cam
with splines.

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1 cam shaft
2 washer
3 lower shaft O-ring
4 body
5 pharos cover
5a metal cover
5b flat cover
6 terminal strip
7 cam springs
8 pharos rotor
9 pharos rotor screw
10 shaft retainers
11 cams
12 limit switch
13 cover O-ring
14 printed circuit board
15 PCB screw
16 elastic pins
17 shaft snap ring
18 metal position indicator
19 washer
20 blind nut
21 upper shft O-ring
22 position indicator screw
23 position indicator
24 enclosure screw
25 identification nameplate
26 plug PG 13.5

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25 VALVE, TYPES KE 71 AND KE 73

1 Body 10 Lock nut

2 Bonnet 12 Gland rings
3 Valve plug 13 Gland spring
4 Valve seat 14 Bonnet gasket
5 Valve stem 15 Bonnet Studs
6 Pin 16 Gland nut gasket
8 Lock nut 17 Bonnet guide
9 Galnd nut 18 Guide bush

Two port single seat valve with equal percentage characteristic for use
with pneumatic actuators (PN5000 Series and N6000 Series) or electric
actuators (EL3400 Series, DN15 to DN50 valves only, EL5060 Series
and EL5500 Series)

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26 ELECTRIC LINEAR ACTUATORS, SERIES EL5600

Maintenance personnel must be suitably qualified in working with

equipment containing hazardous live voltages.

Isolate the actuator from the mains supply before opening the unit.

The actuator is designed as an installation category II product, and

is reliant on the building installation for overcurrent protection and
primary isolation.

Fuses should not be fitted in the protective earth conductor. The

integrity of the installation protective earth system must not be
compromised by the disconnection or removal of other equipment.

The actuator must not be located in such a way that the

disconnecting device is made difficult to operate.

The product may be exposed to interference above the limits of EN

50082-2 if:
- The product or its wiring is located near to a radio transmitter.
- Excessive electrical noise occurs on the mains supply.
- Cellular telephones and mobile radios are used within
approximately one metre of the product or its wiring. The actual
separation necessary will vary according to the power of the
transmitter.

Power line protectors (ac) should be installed if mains supply noise

is likely. Protectors can combine filtering, suppression, surge and
spike arrestors.

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26.1 Operation

The motor rotation is transmitted through low wear and low backlash spur
gears to provide linear movement of the actuator spindle. An anti-rotation
plate is fitted to prevent rotation of the spindle during operation. Top and
bottom travel switches are provided, which are activated by a switching
rod that runs in parallel with the actuator spindle.

The actuator is fitted to the valve with two mounting pillars. The disc
springs transmits the thrust movement to the valve stem. In relation to
the limit switch setting the disc springs are compressed at the valve
closing position to give a defined closing force and valve shut-off.

26.1.1 Manual operation

The handwheel is used to operate the actuator if the power supply has
failed or during installation work such as mounting onto a valve or setting
the limit positions.

• The handwheel is permanently engaged and turns during motor

operation for all the models, with the exception of the EL565_.
• The EL565_ actuator has a handwheel which must be engaged for
manual operation. The ball-headed button on the cover has to be
depressed to engage the handwheel.

Do not exceed the set stroke limits when operating manually.

Do not operate the handwheel using excessive force.

Failure to observe this warning may result in damage to the

actuator.

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26.2 Maintenance

Always make sure that the electrical supply is switched off when
carrying out maintenance on the actuator or valve.

The actuators have a design life of approximately 200 000 full strokes or
alternatively 1.5 million starts (1 start is 1 movement of the spindle). The
maintenance required for the EL5600 actuator range is to inspect the
condition inside of the spindle nut and to lubricate it. If the actuator has
been operating beyond its design limits the spindle nut may require
replacing.

26.3 Spare parts

Maintenance spare kits are available for the actuators. The kits contain
replacement spindle nuts, 'O' rings, the correct lubricating grease, plus
full instructions to carry out the inspection, lubrication / spindle nut
replacement. For more information contact Auramarine Ltd.

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27 STOP BELLOW VALVE, TYPE 234

1 Body
2 Seat ring
3 Bonnet
4 Stem
5 Handwheel
6 Gland
7 Disc
8 Bellow
9 Sleeve
10 Gland packing
11 Bonnet gasket
12 Stud bolts
13 Hexagon nuts

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28 AUTO FILTER 6.62

28.1 General

The fully automatic back-flushing filter is used to filter 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.

The self-cleaning filter basically consists of housing with inlet and outlet
flanges, lower housing with integrated heating chamber (circulation
heating), filter element assembly with individual chambers to
accommodate the filter candles, pneumatic swivel drive with attached
solenoid valve, sludge discharge valve with internal valve tappet and air
receiver, air supply with shut-off valve, non-return valve and pressure
regulator, flushing valve (solenoid valve) with manual initiation,
differential pressure indicator with electrical contact and electric control
system in its own switch box separate from the filter.

Filtration Phase

(see drawing Z40130 BL 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.

Drawing Z40130 BL 1

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Back-Flushing Position

(see drawing Z40130 BL 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.

Drawing Z40130 BL2

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.

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28.2 Commissioning

The following requirements must be met for the commissioning of the

filter:

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.
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).
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. 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 must be guaranteed 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.

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28.3 Control of automatic filter, type 6.62

Selecting parameter assignment mode of A14A1 (LOGO!) controller:

Note in parameter assignment mode, the LOGO! continues execution of the circuit
program.

1. Press ▼ as many times as required to get date into the display

2. Press ESC to change from RUN to parameter assignment mode.

LOGO! changes to parameter assignment mode and opens the parameter

assignment menu:

>Stop
Set Param
Set Clock
Prg Name

Moving from stop to Prg Name by pressing ▼ or ▲ buttons. Selection by pressing

OK. Back by pressing ESC

Description of the four menu items of the parameter assignment menu:

1 Stop is selected to stop the circuit program.

After the program is stopped it can started from the opening menu.
From where also the clock and the summer / winter time can be set by
selecting Clock.

2 Set Param is selected to change the filter parameters.

Selection by pressing ▼ (cursor moves from Stop to Set Param)

and then OK.

Moving from parameter to another by pressing ▼ and ▲ buttons.

Paramers are changed by pressing OK when the parameter to be

changed is in display.

Back by pressing ESC.

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3 Flush counter reset (example)

F CTR
On= 0
Off= 0
Cnt= 21

Flush counter value is in parameter Cnt

Press ► (or◄)as many times as required to move the

cursor on 2. Press ▼ 2 times to change 2 to 0. Press ►
once to move the cursor on 1. Press ▼ once to change 1
to 0. Press OK.

4 Sludge pump run time change (slugde pump is an option which may
not be installed).

SP RUN T
TH =02:00m
TL =00:00s
Ta =00:00

Sludge pump run time value is in parameter TH. 02 means

minutes, 00 means seconds.

Press ► (or◄) as many times as required to move the

cursor on 02:00. Press ▼ or ▲ on numbers to change the
run time. When the run time is changed press OK.

28.3.1 Chamber fill up time change.

FILL UP
T =06:00m

Ta =06:00m

Chamber fill up time is in parameter T 06 means minutes, 00

means seconds.

Press ► (or◄) as many times as required to move the

cursor on 02:00. Press ▼ or ▲ on numbers to change the fill
up time. When the fill up time is changed press OK.

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28.3.2 Flush period change

F PERIOD
T =02:00h

Ta =00:00h

Flush period time value is in parameter T. 02 means hours,

00 means minutes.

Press ► (or◄) as many times as required to move the

cursor on 02:00. Press ▼ or ▲ on numbers to change the
flush period time. When the flush period is changed press
OK.

28.3.3 Flush time change

F TIME
TH =10:00s
TL =10:00s
Ta =00:00

Flush time value is in parameter TH. 10 means seconds, 00

means fractional parts of seconds

Press ► (or◄) as many times as required to move the

cursor on 05:00. Press ▼ or ▲ on numbers to change the
flush time. When the flush time is changed press OK.

28.3.4 Parameter settings

Parameter Factory Setting limits which are

setting not to go under or
exceed
Sludge pump 2 minutes from 2,0 to 5,0 minutes
run time
Chamber fill 6 minutes from 5,0 to 7,0 minutes
up time
Flush period 2 hours from 0,5 to 5 hours
Flush time 10 seconds from 10,0 to 20,0
seconds

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28.3.5 Set clock is selected to set time and date.

Set Clock
Su 00:00
YYYY-MM-DD
2003-01-01

Press ► (or◄) as many times as required to move the

cursor on parameter to be changed. Press ▼ or ▲ to
change the parameter (e.g. day). After all parameters are
correct press OK.

Prg Name is not used.

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28.4 Maintenance

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.

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28.4.1 Servicing Tools

The following special tools are supplied for servicing the filter:

Special key with SW 10 or 14 for dismantling the filter chamber.

Special key for unscrewing the candle elements from the candle holder.

Key for opening the switch box and hand crank for operation during a
power failure.

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28.4.2 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.

28.4.2.1 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.

28.4.2.2 Instruction 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.

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28.4.3 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:

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). Now pull the filter element assembly (5) with the
candle elements (6) up and out of the housing (2).

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.

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.

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.

Now, with the cleaning gun supplied, blow compressed air through the
candles from the inside to the outside.

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 “Manual Cleaning of

the Candle Elements” may only be carried out in a separate tank
using clean solvent. The solvent can then be used again for the next
soaking operation.

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.

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Almost 100% manual cleaning is only possible,using the type 5.04 high-
pressure cleaning unit with BOLL CLEAN 2000. See the separate
description "Filter Cleaning Unit Type 5.04".

28.4.4 Maintenance instructions (bypass filter)

Take the bypass filter out of operation before carrying out

maintenance work on it!

To remove the screen insert, proceed as follows:

1. Slacken venting screw (item 332) of the cover retaining

arrangement and in this way check that the filter housing is
not pressurised.

2. Unscrew the venting screw until the cover panel (item 335)
over the concealed cover screws (item 323) can be
swivelled.

3. Remove cover (item 306) after slackening the cover screws

and pull screen insert out of the filter housing.

4. Clean screen insert with suitable solvents (see KV349) and

then blow through with compressed air from the inside to the
outside.

5. Check seals and replace any damaged seals.

6. Assemble filter in reverse order.

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 15
125 107
119 19 20
121 92 18 43
129 128 21
81,98 17
90 115 54
´ 16
4

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"Y" 77,99
89 79
130-138 120 3
76
108 B-B 44 53

52
115 B 110 123 108
65

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108
45

125
107 8 127
122
115
113 105 C ´
108
68 91

113
26 107
2
31 115
5
140
62 6 124
30 C-C
Document id: IM8569

67
100,101 109
86,87
64
INSTRUCTION MANUAL

63 36
108 61
83
C
27 ´
115 60 9
61
107 29 10
102
59
78
57
51
85 108
69,106 "X"
56
113 35
84 28 55
50
"X" MASSTAB
88,96 BOLL & KIRCH FILTERBAU GMBH
74,75 104 SIEMENSSTRASSE, 50170 KERPEN-SINDORF
DATUM NAME
RUECKSPUELFILTER
37 BEARB. 08.09.97 ROTT BACK-FLUSHING FILTER
GEPR. " SINDORF
"Y"
NORM
1 TYP 6.62
BLATT

66 6.62
BL.
Z40357
ZUST AENDERUNG DATUM NAME

Tel + 358 204 86 5030

129(141)

Fax + 358 204 86 5031

 350
X
355

Z 356
357

AURAMARINE LTD
358
313

359

X 336

P.O.BOX 849
351 352,353 354
332
87 320
325 303 337 338 322 304 315 306

FIN-20101 TURKU
POS.1-150 Z40357

Y 311

335
323
Z
314

308

305
Document id: IM8569
INSTRUCTION MANUAL

340

341,342

314

327,331
307,328

318,334

MASSTAB /
BOLL & KIRCH FILTERBAU GMBH
SIEMENSSTRASSE, 50170 KERPEN-SINDORF

DATUM NAME

BEARB. 15.09.97 BOGDA

GEPR. " SINDORF

FILTERKOMBINATION
NORM FILTER COMBINATION
67 326 317 301 300 310 317 325 333
BLATT
330 36 330 6.62.1 GR.04
BL.
Z40366
ZUST AENDERUNG DATUM NAME

Tel + 358 204 86 5030

130(141)

Fax + 358 204 86 5031

 INSTRUCTION MANUAL 131(141)
Document id: IM8569

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 132(141)
Document id: IM8569

28.5 Spare parts

28.5.1 Type 6.62.1

Document id 40112, 16.2.2004

pos id part qty

0001 6139924 housing lower part 1
0002 6139920 housing 1
0003 6130313 cover 1
0004 5700318 distance pice 1
0005 6139930 filter candle support 1
0006 filter element 4
0007 5906594 cover 1
0007 5218298 nozzle pos. 1
0007 6712641 bow 1
0007 2000266 slotted chesse head 2
0008 2610023 float 1
0008 2611123 pin 1
0008 3530032 double nipple 1
0009 2708947 taper rolling bearin 1
0010 5000292 bushing 1
0011 5130371 filter candle coveri 1
0011 2300374 bow 1
0011 2300601 quick fixing device 1
0015 6100317 carrier 1
0016 5100316 control disc 1
0017 2706240 free wheel 1
0018 2206988 disc 1
0019 5004718 driveshaft 1
0020 2206959 retaining ring for s 1
0021 2201003 locking ring 1
0026 6130344 air reservoir 1
0027 6139926 housing 1
0028 5001563 valve seat 1
0029 5000353 valve ram 1
0030 5100355 piston screw 1
0031 5100356 bushing 1
0035 5702156 counter flange 1
0036 2800063 square counter flang 2
0037 5004049 flange 1
0042 2202238 disc 1
0043 2401000 keys 1
0044 2300016 spring type straight 1
0045 2300016 spring type straight 1
0046 2310039 spring type straight 1
0050 3030180 gasket 1
0051 3030729 gasket 1
0052 3030180 gasket 1
0053 3090218 gasket 2
0054 3048235 gasket 1
0055 3098361 gasket 1
0056 3030063 gasket 1
0057 3040158 gasket 1
0059 3031077 gasket 1
0060 3098361 gasket 1
0061 3094563 gasket 3

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 133(141)
Document id: IM8569

0062 3031047 gasket 1

0063 3038188 o-ring 1
0064 2785451 piston 1
0065 3132369 gasket 1
0066 3384063 gasket 1
0067 3380001 gasket 2
0068 3270008 seal 1
0069 3270004 gasket 1
0074 2100011 hexagon nut 6
0075 2000482 stud bolt 6
0076 2000155 hexagon socket head 6
0077 2000131 hexagon socket head 4
0078 2000122 hexagon socket head 1
0079 2000153 hexagon socket head 4
0081 2000122 hexagon socket head 4
0082 2100006 hexagon nut 2
0083 2000143 slotte chesse head 4
0084 2000144 hexagon socket head 4
0085 2000147 hexagon socket head 4
0087 2100006 hexagon nut 8
0088 2000001 stud 6
0089 2000122 hexagon socket head 2
0090 2002155 hexagon socket 2
0091 2002155 hexagon socket head 2
0092 2000967 hexagon socket head 2
0093 2000122 hexagon socket head 4
0094 2000261 slotted cheese head 2
0096 2100004 hexagon nut 6
0097 2000004 stud bolt 2
0098 2209799 despring ring 4
0099 2200235 spring ring 4
0100 2201574 spring ring 1
0101 2200007 washer 1
0102 2209021 disc 1
0104 2000205 hexagon head screw p 2
0105 2001772 hexagon head screw p 1
0106 2000189 hexagon head pipe pl 1
0107 2500024 screwing 4
0108 2500025 screwing 6
0109 2505496 screwing 1
0110 2564886 spacer block 2
0112 2560356 angle ball cock 1
0113 2560063 angle ball cock 2
0115 0600642 6.62 dn 40, z40642 tube 1
0119 4503501 double piston part t 1
0120 0550001 36.2 p = 0.8 dda 09322 08 pressure different contact indicator 1
0121 2656655 5/2-ventil valve 1
0121 4206553 coil 1
0121 4105912 receptacle 1
0122 2656655 5/2-ventil valve 1
0122 4206553 coil 1
0122 4105912 receptacle 1
0123 2650017 high pressure control 1
0124 2608775 non return valve 1
0125 2614171 sound absorber 2
0126 2600044 manometer 1
0127 2660005 safety valve 1
0128 4200057 limit switch 1
0129 4102567 screwing 1
0130 5950197 connector box 1

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 134(141)
Document id: IM8569

0131 8450198 cover 1

0132 3380199 gasket 1
0134 4105616 binder 10
0134 4105617 binder 4
0134 4100015 distance plate 3
0136 2000258 slotted cheese head 2
0137 4105801 assembly rail 1
0138 4100101 cable gland 6
0138 4100103 cable screwing 1
0140 9401690 wn26 name plate 1
0141 9407569 label " out " 1
0141 9400997 label " in " 1
0141 9407396 label " mud dra 1
0141 9402898 label air release 1
0141 9403614 label "compressed air” 1
0145 6705032 key for unscrewing T 1
0150 steuerung n.auftrag/ 1
0160 5065912 flushing guide plate 1
0162 5003207 pressure piece 1
0165 2708946 deep groove ball thr 1
0167 3030060 gasket 1
0168 2310110 spring 1
0169 2000123 hexagon socket head 1
0180 3636624 gasket set 1
0300 6235819 housing 1
0301 6329196 cock 1
0303 6406236 cover 1
0304 8650098 reversing handle 1
0305 6436188 bypassf. housing 1
0306 6432960 cover 1
0307 6532077 heating chamber 1
0308 1174632 filter element 1
0310 3031222 gasket 1
0311 3034299 gasket 1
0313 3421241 gasket 1
0314 3031525 gasket 2
0315 3270002 gasket 1
0317 3380001 gasket 4
0318 3380049 gasket 1
0320 2307145 fixing device 1
0322 2000156 hexagon socket head 2
0323 2000143 slotted chesse head 6
0325 2000004 stud bolt 16
0326 2000004 stud bolt 8
0327 2000001 stiftschraube stud 4
0328 2004354 gewindestift set screw 2
0330 2100006 hexagon nut 16
0331 2100004 hexagon nut 4
0332 5204517 bolt 1
0333 2000207 hexagon head screw p 1
0334 5000011 counter flange 1
0335 6706685 locking plate 1
0336 3039056 gasket 1
0337 9401114 label 1
0338 9400220 label "information F” 1
0340 5700232 bottom fastening 1
0341 2000143 slotted chesse head 2
0342 2200007 washer 2
0350 0550001 4.36.2 p = 0.8 dda 09322 08 pressure different. contact indicator 1
0351 2000121 hexagon socket head 2

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 135(141)
Document id: IM8569

0352 2000123 hexagon socket head 2

0353 2100003 hexagon nut 2
0354 5700108 plate 1
0355 2500008 angle 2
0356 2500025 screwing 2
0357 2500083 nipple 2
0358 2560770 ball valve 2
0359 2500024 screwing 2

28.5.2 Type 6.62

Document 0637865, 3.12.2004

pos id part qty

00001 6139924 housing lower part 1
00002 6139920 housing 1
00003 6130313 cover 1
00004 5700318 distance piece 1
00005 6139930 sieve body 1
00006 1104422 filter candle according to order 4
00007 5906594 cover 1
00007 5218298 nozzle 1
00007 6712641 bow 1
00007 2000266 slotted cheese head screw 2
00008 2610023 float 1
00008 2611123 pin 1
00008 3530032 threaded pipe fitting 1
00009 2708947 deep groove ball bearing 1
00010 5000292 bushing 1
00011 5130371 cover disc 1
00011 2300374 bow 1
00011 2300601 quick fixing device 1
00015 6100317 carrier 1
00016 5100316 control disc 1
00017 2706240 freewheel 1
00018 2206988 supporting disc 1
00019 5004718 drive shaft 1
00020 2206959 locking ring 1
00021 2201003 locking ring 1
00026 6130344 air reservoir 1
00027 6139926 housing mud drain 1
00028 5001563 valve face 1
00029 5000353 valve ram 1
00030 5100355 piston screw 1
00031 5100356 damper bushing 1
00035 5702156 square counter flange 1
00036 2800063 square counter flange 2
00037 5004049 flange heating 1
00043 2401000 feather key 1
00044 2300016 Spring Type Straight Pin 1
00045 2300016 Spring Type Straight Pin 1
00046 2310039 Spring Type Straight Pin 1
00050 3030180 o-ring 1
00051 3030729 o-ring 1
00052 3030180 o-ring 1
00053 3090218 o-ring 2
00054 3048235 o-ring 1
00055 3098361 o-ring 1

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 136(141)
Document id: IM8569

00056 3030063 o-ring 1

00057 3040158 o-ring 1
00059 3031077 o-ring 1
00060 3098361 o-ring 1
00061 3094563 o-ring 3
00062 3031047 o-ring 1
00063 3038188 o-ring 1
00064 2785451 seal piston 1
00065 3132369 o-ring 1
00066 3384063 flat gasket heating 1
00067 3380001 high pressure gasket 2
00068 3270008 gasket 1
00069 3270004 gasket 1
00074 2100011 hexagon nut 6
00075 2000482 stud bolt 6
00076 2000155 hexagon socket head cap screw 6
00077 2000131 hexagon socket head cap screw 4
00078 2000122 hexagon socket head cap screw 1
00079 2000153 hexagon socket head cap screw 4
00081 2000122 hexagon socket head cap screw 4
00082 2100006 hexagon nut 2
00083 2000143 hexagon socket head cap screw 4
00084 2000144 hexagon socket head cap screw 4
00085 2000147 hexagon socket head cap screw 4
00086 2000035 hexagon screw 8
00087 2100006 hexagon nut 8
00088 2000001 stud bolt 6
00089 2000122 hexagon socket head cap screw 2
00090 2002155 hexagon socket head cap screw 2
00091 2002155 hexagon socket head cap screw 2
00092 2000967 hexagon socket head cap screw 2
00093 2000122 hexagon socket head cap screw 4
00094 2000261 slotted cheese head screw 2
00096 2100004 hexagon nut 6
00097 2000004 stud bolt 2
00098 2209799 spring ring 4
00099 2200235 spring ring 4
00100 2201574 spring ring 1
00101 2200007 disc 1
00102 2209021 disc 1
00104 2000205 screwed sealing plug 2
00105 2001772 screwed sealing plug 1
00106 2000189 screwed sealing plug 1
00107 2500024 screwing 4
00108 2500025 screwing 6
00109 2505496 screwing 1
00110 2564886 removeable double nibble 2
00112 2560356 angle ball valve 1
00113 2560063 angle ball valve 2
00115 0600642 tubing set 1
00116 2500025 screwing 1
00119 4503501 double piston slewing gear 1
00120 9902572 differential pressure indicator ace. t 1
00121 4105912 connector plug 1
00121 2656655 solenoid valve 1
00121 4206553 coil 1
00122 2656655 solenoid valve 1
00122 4206553 coil 1
00122 4105912 connector plug 1
00123 2650017 high pressure control device 1

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 137(141)
Document id: IM8569

00124 2608775 non return valve 1

00125 2614171 sound absorber 2
00126 2600044 pressure gauge 1
00127 2660005 safety valve 1
00128 4200062 limit switch 1
00129 4160351 angle cable screwing 1
00129 4160349 reducing ring 1
00130 5950197 connection box 1
00131 8450198 cover for connection box 1
00132 3380199 flat gasket 1
00134 4105616 clamp 10
00134 4105617 clamp 4
00134 4100015 distance plate 3
00136 2000258 slotted cheese head screw 2
00137 4105801 mounting rail 1
00138 4100085 cable gland 6
00138 4100086 cable gland 1
00140 9401690 type plate 1
00141 9407569 label: "in / out" 1
00141 9400997 label: "on / off" 1
00141 9407396 label: "mud drain" 1
00141 9402898 label 1
00141 9403614 label: "compressed air connection" 1
00145 6705032 key for unscrewing the filter element 1
00150 4300000 control box according to order 1
00160 5065912 flushing bush 1
00162 5003207 thrust piece 1
00165 2708946 deep groove ball bearing 1
00167 3030060 o-ring 1
00168 2310110 shaft spring 1
00169 2000123 hexagon socket head cap screw 1

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 138(141)
Document id: IM8569

TYP4.36.2
06.01.98
75

- +

G1/4

29

24
93 G1/4
95 PG13.5
40.5 52
97

CIRCUIT DIAGRAM
7 1 1a
20
P1 P2

2 3a 3
SPECIFICATION:
PROTECTION CLASS: IP 65

ELECTR. DATA: SWITCHING VOLTAGE V= MAX.= 250 220

FREQUENCY HZ MAX.= 0-60 0-60
SWITCHING CURRENT A MAX.= 1 0.8
MAKING AND/OR BREAKING CAPACITY
W/VA MAX.= 60/60 40/60
MATERIAL : GD - ALUMINIUM
RATING : MAX. PRESSURE 100 BAR
MAX. TEMPERATURE 150░C

RANGES OF PRESSURE DELTA P = 0 - 0.5 BAR

DIFFERENTIAL : 0 - 0.8 BAR TO BE SPECIFIED
0 - 1.2 BAR WHEN ORDERING
0 - 2.0 BAR
0 - 3.0 BAR
DESCRIPTION:

THE PURPOSE OF THIS DEVICE IS THE MEASUREMENT, AND VISUAL INDICATION

OF THE DIFFERENCE IN PRESSURE BETWEEN TWO POINTS, AND THE ESTABLISH-
MENT OF AN ELECTRICAL CONTACT WHEN THE PRESSURE DIFFERENTIAL ATTAINS
A SPECIFIED FIGURE.

METHOD OF OPERATION:

A PLUNGER SEALED BY A DIAPHRAGM SEPARA TES THE SPACE UNDER PRESSURE

INTO TWO CHAMBERS. A PRE-LOADED SPRING CAUSES THE PLUNGER TO TAKE
UP ITS ZERO POSITION WHEN THE PRESSURE DIFFERENCE DELTA P IS ZERO.
AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PLUNGER IS
FORCED TO MOVE AGAINST THE SPRING. AT THE SAME TIME, AN INDICATOR
DISC IS MOVED MAGNETICALLY, AND THEREFORE VIRTUALLY WITHOUT
FRICTION, AND THE TWO REED CONTACTS ARE ACTUATED.

THE RED SEGMENT OF THE INDICATOR DISC IS VISIBLE OVER A PRESSURE

RANGE EQUAL TO 20-100% DELTA P . THE FIRST REED CONTACT IS ACTUATED
AT 75% DELTA P, AND THE SECOND AT 100% DELTA P.
DIFFERENTIAL PRESSURE CONTACT INDICATOR
AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030
FIN-20101 TURKU Fax + 358 204 86 5031
 B

AURAMARINE LTD
3

P.O.BOX 849
FIN-20101 TURKU
GEKLEBT
CEMENTED
COLLE

3a 3 2 1a 1
A

BEI BESTELLUNG ANGEBEN

TO BE MENTIONED IN CASE OF ORDER
11 A MENTIONNER LORS DE LA COMMANDE
Document id: IM8569

7 AUFTR.NR.:
ORDER NO. TYP 4.36.2
NO DE COMMANDE
INSTRUCTION MANUAL

10

11 ROLLMEMBRAN DIAPHRAGM DIAPHRAGME

10 FEDER SPRING RESSORT
A-B 7 KOLBEN PISTON PISTON
3 DICHTUNG GASKET JOINT
POS.NR. BEZEICHNUNG DESIGNATION DESIGNATION

ERSATZTEILZEICHNUNG ZUM TYP 4.36.2 UND 4.46.2

SPART PARTS DRAWING PLAN DES PIECES DE RECHANGE

11.02.94
BOLL & KIRCH FILTERBAU GMBH Z21434
SIEMENSSTRASSE, 50170 KERPEN-SINDORF

Tel + 358 204 86 5030

139(141)

Fax + 358 204 86 5031

 INSTRUCTION MANUAL 140(141)
Document id: IM8569

29 PRESSURE VESSELS

To ensure faultless operation, check regularly the operation of the pressure relief valve and any
other safety devices visually. If a safety device is found damaged it must be replaced. The
internal and external condition of the vessel is inspected.

NOTE: The manufacturer of the vessel shall be contacted if it is established

that the vessel has been deformed, damaged, corroded, or if its surface
coating is torn. Repair measures must be agreed with the manufacturer
of the pressure equipment.

NOTE: The decisions of the local pressure equipment authorities in the target
country apply for any possible repair and modification work.

1. To avoid damaging the pressure vessel, do not exceed the maximum allowed
operating pressure which is shown on the vessel's nameplate. Use the relief
valve.

2. Do not exceed the maximum allowed operating temperature which is shown on

the pressure vessel's nameplate. As the temperature rises, the pressure rises
too. Use the relief valve.

3. Do not touch the surface of the vessel when its internal temperature exceeds 60
°C. The vessel surface is burning hot. Be careful with the hot contents.

A commissioning inspection, i.e. the first periodic service, is performed for pressure vessels
which are to be registered. The first periodic inspection is performed by the notified body and
the owner or the holder is obliged to apply to the notified body for the performance of the
inspection.

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031
 INSTRUCTION MANUAL 141(141)
Document id: IM8569

30 HOW TO ORDER SPARE PARTS

Identification of needed part

When ordering spare parts, please mention the following:

1 Serial number of the unit

(welded on the bottom beam of the unit frame)

1234

2 Part number from the part list

3 Serial number of the part to be replaced

(mentioned in the rating plate of the part)

Ordering address:

Auramarine Ltd., After Sales Dept., P.O. Box 849, FIN-20101 TURKU
Fax +358 204 86 5031
Tel +358 204 86 5030

In case of guarantee part(s), please return the damaged part(s) to the above
mentioned address.

AURAMARINE LTD P.O.BOX 849 Tel + 358 204 86 5030

FIN-20101 TURKU Fax + 358 204 86 5031