Operation and maintence maunal of boiler feed pump

GEA BGR ENERGY SYSTEM INDIA LIMITED

OPERATION & MAINTENANCE MANUAL

FOR

DEBRIS FILTER

GEA DOC. NO.GI 3097 200 09 054 Rev.A

KORADI TPS EXPANSION PROJECT UNITS 8, 9 & 10 - 3 x 660 MW

PROJECT NO. GBX/3097/2011

OPERATION & MAINTENANCE MANUAL FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A GBX/3097/2011 Sheet 1

C O N T E N T S

SECTION I INTRODUCTION ................................................................................................................... 4

1.1 DEBRIS IN C.W. SYSTEM........................................................................................................................... 5 1.1.1 MECHANISM ............................................................................................................................................................... 5 1.1.2 SOURCE OF LODGED OBSTRUCTIONS ................................................................................................................ 5

1.2 GEA BGR DEBRIS FILTER ......................................................................................................................... 6 1.2.1 DESCRIPTION ............................................................................................................................................................. 6 1.2.2 SPARE PARTS .............................................................................................................................................................. 7

1.3 SOLUTION ..................................................................................................................................................... 8

SECTION II DESCRIPTION OF COMOPONENTS ............................................................................. 9

2.1 DEBRIS FILTER (C11 / C12) ...................................................................................................................... 10 2.1.1 D.P. MEASURING SYSTEM ..................................................................................................................................... 10 2.1.2 CONTROL PANEL .................................................................................................................................................... 10

SECTION III LEADING PARTICULARS .............................................................................................. 11

3.1 GENERAL INFORMATION ..................................................................................................................... 12

3.2 DEBRIS FILTER C11 ............................................................................................................................... 12

3.4 WORM PLANETARY GEAR B21 ........................................................................................................... 13

3.4 GEARED MOTOR DRIVE T21 ............................................................................................................... 13

3.5 BALL VALVES ............................................................................................................................................. 15

3.6 BUTTERFLY VALVE M31 ...................................................................................................................... 16

3.7 ACTUATOR FOR BUTTERFLY VALVE T31 ......................................................................................... 16

3.8 D.P. TRANSMITTER D01....................................................................................................................... 18

3.9 DP INDICATING SWITCH D03 ............................................................................................................ 19

3.10 D.P. INDICATOR E01, E02, E03, E04 ................................................................................................... 20

3.11 INTERCONNECTING PIPING ................................................................................................................ 21

3.12 CONTROL PANEL S01 .......................................................................................................................... 21

SECTION IV PRECONDITION ............................................................................................................... 22

4.1 STORAGE/PRESERVATION ................................................................................................................... 23 4.1.1 EQUIPMENT & ACCESSORIES .............................................................................................................................. 23 4.1.2 ELECTRICAL & ELECTRONIC ITEMS .................................................................................................................. 23

4.2 SAFETY INSTRUCTIONS......................................................................................................................... 24 4.2.1 GENERAL ................................................................................................................................................................... 24 4.2.2 ELECTRCITY .............................................................................................................................................................. 24 4.2.3 PRESSURE ................................................................................................................................................................... 25 4.2.4 TEMPERATURE ......................................................................................................................................................... 25

4.3 GENERAL INSTRUCTIONS .................................................................................................................... 26 4.3.1 OPTIMISATION OF THE WATER CIRCULATION ............................................................................................. 26

SECTION V REQUIRED TOOLS AND MATERIALS ........................................................................ 27

5.1 REQUIRED TOOLS AND TACKLES ..................................................................................................... 28



SECTION VI INSTALLATION INSTRUCTION ................................................................................. 29

6.1 DEBRIS FILTER ........................................................................................................................................... 30

6.2 DEBRIS DISCHARGE LINE ..................................................................................................................... 30

6.3 BALL VALVES ............................................................................................................................................. 30

6.4 D.P. MEASURING SYSTEM ..................................................................................................................... 30

6.5 ISOLATION VALVES ................................................................................................................................ 31

6.6 CONTROL PANEL...................................................................................................................................... 31

6.7 CABLING ...................................................................................................................................................... 31

6.8 PRESERVATION MEASURES BEFORE COMMISSIONING .......................................................... 32

SECTION VII SUPERVISION AND FINAL ASSEMBLY .................................................................. 33

7.1 COMPONENTS ........................................................................................................................................... 34 7.1.1 DEBRIS FILTER, WORM PLANETARY GEAR AND GEARED MOTOR DRIVE .......................................................... 34 7.1.2 DEBRIS DISCHARGE VALVE WITH ACTUATOR .............................................................................................. 34 7.1.3 DEBRIS DISCHARGE PIPE ...................................................................................................................................... 35

7.2 D.P. MEASURING SYSTEM ..................................................................................................................... 35 7.2.1 D.P. TRANSMITTER ................................................................................................................................................. 35 7.2.2 D.P. INDICATOR ....................................................................................................................................................... 35 7.2.3 D.P. ISOLATION VALVES (BALL VALVES) ......................................................................................................... 36

7.3 CONTROL PANEL...................................................................................................................................... 36

7.4 TIMER SETTING ........................................................................................................................................ 36

SECTION VIII COMMISSIONING........................................................................................................ 37

8.1 GENERAL INSTRUCTION ....................................................................................................................... 38

8.2 FILLING THE SYSTEM WITH WATER ................................................................................................. 39

8.3 TRIAL OPERATION IN AUTOMATIC MODE ................................................................................... 40 8.3.1 DIFFERENTIAL PRESSURE MEASURING SYSTEM ........................................................................................... 40

8.4 TRIAL OPERATION IN AUTOMATIC MODE (SHUT DOWN) ..................................................... 41

SECTION IX OPERATIONS ..................................................................................................................... 42

9.1 SYSTEM OPERATION .............................................................................................................................. 43 9.1.1 SALIENT FEATURES ................................................................................................................................................. 43 9.1.3 MANUAL MODE ...................................................................................................................................................... 44 9.1.4 AUTOMATIC MODE ................................................................................................................................................. 44 9.1.5 SETTINGS OF TIMERS (PLC INTERNAL TIMERS) ............................................................................................ 46 9.1.7 CAUSES FOR FAIL .................................................................................................................................................... 46

SECTION X SERVICE & MAINTENANCE .......................................................................................... 48

10.1 GENERAL MAINTENANCE .................................................................................................................... 49

10.2 MAINTENANCE OF DEBRIS FILTER ................................................................................................... 49

SECTION XI LUBRICATION ................................................................................................................... 51

11.1 PLANETARY WORM GEAR BOX ........................................................................................................... 52

11.2 GEARED MOTOR DRIVE ........................................................................................................................ 53

11.3 ACTUATOR FOR DEBRIS DISCHARGE VALVE .............................................................................. 54



SECTION XII TROUBLESHOOTING .................................................................................................... 55

12.1 DEBRIS FILTER ........................................................................................................................................... 56

12.2 BLOCKED TUBES ....................................................................................................................................... 57

12.3 D.P. TRANSMITTER .................................................................................................................................. 58

SECTION XIII DOCUMENTATION ...................................................................................................... 59

13.1 BALL VALVES ............................................................................................................................................. 60 13.1.1 PRIOR TO INSTALLATION ................................................................................................................................ 61 13.1.2 INSTALLATION ................................................................................................................................................... 61 13.1.3 OPERATION AND MAINTENANCE ............................................................................................................... 62 13.1.4 DIS-ASSEMBLY ..................................................................................................................................................... 62 13.1.5 REASSEMBLY ........................................................................................................................................................ 63

13.2 ACTUATOR FOR DEBRIS DISCHARGE VALVE (SG 07.1) ............................................................. 64 13.2.1 TECHNICAL DATA ............................................................................................................................................. 65 13.2.2 ADDITIONAL INFORMATION TO THE WIRING DIAGRAM .................................................................... 68 13.2.3 STORAGE ............................................................................................................................................................... 69 13.2.4 TYPE OF DUTY / MOUNTING POSITION ...................................................................................................... 69 13.2.5 MOUNTING OF HANDWHEEL / MANUAL OPERATION ........................................................................ 70 13.2.6 MOUNTING TO THE VALVE ............................................................................................................................ 70 13.2.7 ELECTRIC CONNECTION ................................................................................................................................. 71 13.2.8 SETTING OF END STOPS FOR PART-TURN ACTUATORS ON BUTTERFLY VALVES ......................... 73 13.2.9 CHANGING THE SWING ANGLE.................................................................................................................... 73 13.2.10 OPENING THE SWITCH COMPARTMENT .................................................................................................... 75 13.2.11 SETTING THE LIMIT SWITCHING ................................................................................................................... 75 13.2.12 SETTING THE TORQUE SWITCHING ............................................................................................................. 76 13.2.13 TEST RUN .............................................................................................................................................................. 77 13.2.14 SETTING THE ELECTRONIC POSITION TRANSMITTER (RWG) .............................................................. 78 13.2.15 SETTING OF MECHANICAL POSITION INDICATOR ................................................................................ 79 13.2.16 CLOSING THE SWITCH COMPARTMENT..................................................................................................... 80 13.2.17 SETTING THE OPERATING TIME ................................................................................................................... 80 13.2.18 ACTUATOR CONTROLS AUMA MATIC ........................................................................................................ 81 13.2.19 ELECTRONIC POSITIONER (OPTION) ............................................................................................................ 83 13.2.20 MAINTENANCE .................................................................................................................................................. 91 13.2.21 LUBRICATION ...................................................................................................................................................... 91 13.2.22 SPARE PARTS ...................................................................................................................................................... 92 13.2.23 SPARE PARTS LIST CONTROLS ....................................................................................................................... 94

13.3 DP TRANSMITTER .................................................................................................................................... 96 13.3.1 INSTALLATION ................................................................................................................................................... 97 13.3.2 LOCATION ............................................................................................................................................................ 97 13.3.3 SOURCES OF ERROR ........................................................................................................................................... 98 13.3.4 MOUNTING .......................................................................................................................................................... 98 13.3.5 WIRING .................................................................................................................................................................. 99 13.3.6 CALIBRATION .................................................................................................................................................... 100 13.3.7 SETTING OF JUMPERS ...................................................................................................................................... 101

SECTION XIV CATALOGUES .............................................................................................................. 103

SECTION XV DRAWINGS ..................................................................................................................... 123

NOTE: KKS NUMBERS MENTIONED IN THE MANUAL ARE FOR UNIT 8 ONLY. FOR UNITS 9 & 10, FIRST TWO DIGITS OF THE KKS NUMBER ARE TO BE READ AS 09 AND 10 RESPECTIVELY.



SECTION I

INTRODUCTION



1.1 DEBRIS IN C.W. SYSTEM

The Problem

Debris, such as shells, sticks, stones and plastics are common cause of failure in Condenser and Plate Heat Exchangers. Localised attack (erosion - corrosion) leading to rapid failure in the consequence. It has been reported that this is the major cause of failures at coastal locations.

The Solution

Improvements in the primary screening would only lead to a partial solution. It would not solve the problem of debris from within the C.W. System itself. Similarly, chlorination can be used to kill mussels etc. but will not prevent the shells entering into the Condenser / Plate Heat Exchanger. Recognition of these problems and the severe consequences of debris trapped in the Plate Heat Exchanger/Condenser tubes are meant that some form of secondary screening, located as close as possible to the inlet line, is now regarded as essential. GEA-BGR offers a range of Debris Filters, which fulfill these requirements.

1.1.1 Mechanism

When water flows through Plate Heat Exchangers/Condenser Tubes, a shear stress is produced in the wall surface, which is dependent on the C.W. velocity. For each alloy there is a critical shear stress (Corresponding to a critical C.W. velocity) above which erosion - corrosion will occur.

The free cross-sectional area at a lodged obstruction is reduced and this leads to a corresponding increase in the C.W. Velocity locally (to maintain volume flow). This increase may then be sufficient for the critical shear stress to be exceeded and for erosion - corrosion to take place. Erosion - Corrosion is particularly a rapid form of attack. The protective oxide film is removed and attack of the plate material can therefore proceed virtually unimpeded. Plate penetration in a few thousand hours is common.

Where an extremely large area is blocked by debris, it is possible that the C.W. velocity in the remaining area will be sufficiently high to cause film breakdown and subsequent erosion - corrosion.

1.1.2 Source of lodged obstructions

The troublesome debris can come from one or two possible sources:

It penetrates the primary screening by way of gaps in the primary screening, allowing debris to get through, there is carry-over on the travelling band screens, the debris is fibrous and simply penetrates the screens or the prescreening system is overloaded and the pressure - release flap is opened.

It originates from within the C.W. system. This could typically be pieces of concrete or stones from the C.W. culverts, packing material from within the cooling tower or bio-species which have grown to maturity in the C.W. System. Mussels, barnacles etc. can easily penetrate the primary screening in the larval state and grow rapidly under the very favourable conditions (warmth, ready supply of nutrients and oxygen) pertaining in the



C.W. intake system. Sooner or later, the mussels etc. get detached and the shells enter the plate causing blockages.

1.2 GEA BGR DEBRIS FILTER

1.2.1 DESCRIPTION

Equipment for continuously removing debris, such as mussels, fish, grass, leaves, pieces of wood, plastics from circulating water (C.W.) system.

The Standard

Strainer Wedge Wire Screen size 5 x 8mm is chosen to meet the actual site condition.

Flushing cycle activated by differential pressure and time relay for normal flushing cycle of 3 minutes [Adjustable].

Fully automatic operation with an option of manual operation, if desired.

Filter Type "V"

The Strainer is characterized by its compactness, the housing diameter being equal to the diameter of the C.W. inlet. It can be supplied in elbow design or as short straight length.

The DEBRIS EXTRACTOR is box shaped and located inside of the Strainer Basket, extending along the whole length of the basket wall. The gap between the extractor and the basket wall is 30-60 mm.

In this design, the strainer basket is fixed and the Debris Extractor is rotated around it during cleaning. The CW enters the housing and cone shaped strainer basket axially. The debris discharge pipe guides the debris to the Outlet Pipe.

The compact design of the "V"-type STRAINER means that the ratio of the free cross-section of the strainer to the C.W. inlet cross-section. Requirement

The operation of GEA-BGR Cleaning System(s) in connection with GEA-BGR Debris Filter(s) should lead to a smooth-running, trouble-free operation with the best possible efficiency of the condenser.



1.2.2 SPARE PARTS

S. No. Description Part No

Qty. / System

Recommended Qty./System

Shell

1 Manhole - O Ring 51109 2 1

Gear Sealing Assembly

2 Sleeve 21331 1 1

3 Rear Bearing & Flange 21332, 21365

1 each 1 each

4 Front Bearing Disc 21334 1 1

5 Worm Gear Box 21335 1 1

6 O-ring 21336, 21351

1 each 1 each

7 U-Seal 21338 2 1

8 Shaft Seal 21340 2 1

Screen Basket

9 Screen Basket Bearing 21508 1 1

10 Disc 21509 1 1

Drive Shaft

11 Drive Shaft 21701 1 1

12 Protection Muff 21702 2 1

13 Coupling 21713 1 1

14 O Ring 21724 1 1

15 Gear Motor Drive 21737 1 1

16 Double Angular Contact Bearing 21738 1 1

17 Deflector Disc 21740 1 1

18 Internal Circlip 21741 1 1

19 Oil Seal 21742 1 1

20 External Circlip 21744 1 1

Debris Outlet & Debris Outlet Support

21 Butterfly Valve (300 NB) -- 1 1

22 Actuator for Butterfly Valve (SG 10.1-16) -- 1 1

23 Debris Outlet Gasket 21811 1 1

24 Bearing Sleeve 21823 1 1

25 V-Ring 21824 1 1

26 Turn Buckle Assembly Set (Debris Outlet Support) Sets 4 Sets 2 Sets

Valves & Accessories

27 Ball Valve (DN 25) -- 4 2

28 Seat – Ball Valve (DN 25) -- 4 2

29 Gland – Ball Valve (DN 25) -- 4 2

30 Gasket – Ball Valve (DN 25) -- 8 4

31 DP Transmitter -- 1 1

32 DP Indicating Switch -- 1 1



1.3 SOLUTION

Supplier Provides Customer Provides

A detailed operating manual containing sufficient information of all components to ensure satisfactory operation and when necessary, enable repairs to be carried out.

Operation of the GEA-BGR DEBRIS FILTER according to the operating instructions.

Operating instructions, i.e. an extract from the operating manual for operating personnel.

Maintenance and repair work as specified in the detailed operating manual.

Final assembly check. Nomination of personnel to be trained in operation and maintenance activities.

Commissioning of the system

Instruction to the operating personnel.

Advice on and/or carrying out servicing and repair work.

Detailed training of the operating personnel by means of operating instructions.

Erection, Commissioning work and other modifications to the system(s) are to be carried out. We can take no responsibility for breakdowns and damage caused by failure to comply with the OPERATING INSTRUCTIONS. Repairs if any should always be carried out in co-operation with our FIELD ENGINEERING DEPARTMENT.

For advice please contact :

GEA-BGR ENERGY SYSTEM INDIA LIMITED 443, 1st FLOOR, GUNA BUILDINGS,

ANNA SALAI, TEYNAMPET CHENNAI - 600 018. INDIA. TEL - 00 91 - 44 - 2433 5958 FAX - 00 91 - 44 - 2434 3374

E-Mail - [email protected]



SECTION II

DESCRIPTION OF COMOPONENTS



The description of various components which form part of Debris Filter is given below :

2.1 DEBRIS FILTER (C11 / C12) The Debris Filter is of shell type construction with flanged ends. The Debris Filter consists of a screen basket, Extraction arm assembly with rotation motor drive and a Debris Discharge Unit.

The basket prevents the Debris from entering the main Inlet line. The cleaning action is activated by the rotation motor. The accumulated debris is collected in the pipe and discharged through the discharge unit.

The discharge unit comprises of a pipeline running through the central axis of the separator and an Actuator operated valve that drains the Debris out.

2.1.1 D.P. MEASURING SYSTEM

The D.P. Measuring System constantly monitors the Differential Pressure across the Debris Filter. This is done to avoid any damage to the screen basket. When the Differential Pressure exceeds a preset value, the extraction arm assembly activated by the rotation motor drive, cleans the basket. The above system consists of :

D.P. Transmitter [D01 / (08PAF21CP181 / 08PAF21CP182)] senses the Differential Pressure and transforms this into an electrical output.

Isolation Valves [N36, N37 / (08PAF21AA301, 08PAF21AA302 / 08PAF21AA305, 08PAF21AA306)] isolate the D.P. Transmitter (D01) from the Cooling Water in case of Service requirements.

Isolation Valves [N38, N39 / (08PAF21AA303, 08PAF21AA304 / 08PAF21AA307, 08PAF21AA308)] isolate the D.P. Indicating Switch [D03 / (08PAF21CP251 / 08PAF21CP252)] from the Cooling Water in case of Service requirements.

2.1.2 CONTROL PANEL

The Control Panel (S02) is of PLC based, which enables Automatic and Manual Operation of the System. The Panel is provided with a Mimic Diagram that explains the system functioning. Necessary Audio Visual annunciation is provided in the Mimic for easy operation and for fault tracing.



SECTION III

LEADING PARTICULARS



S. NO. DESCRIPTION DATA / PARAMETERS

3.1 GENERAL INFORMATION i) No. of Strainers / Filter required 6 Nos. ii) Liquid handled Clarified water

iii) Size of Debris Filter ID-2350 NB x 14mm tk

iv) Filter type / duty Online / Continuous

v) Location Condenser Inlet

vi) Design Data - Operating Pressure < 5 Kg/cm2 (g) - Design Pressure 5.0 Kg/Cm2(g) and Full Vacuum - Design Temperature 60 oC - Flow rate through filter - Normal 38700 cu.m/hr

- Maximum 41910 cu.m/hr

v) Type of suspended matter likely to enter the filter Typical debris encountered in closed

circuit CW system with Cooling tower < 30mm

vi) Differential pressure at Clean condition 50 mbar

vii) Differential pressure measuring system

set pressure for initiating flushing/ backwashing for alarm / annunciation 80 mbar

3.2 DEBRIS FILTER C11 (08PAF21AT001 / 08PAF21AT002) i) Make GEA BGR India ii) Quantity 6 Nos. iii) Design Data - Design code ASME Sec.VIII Div.I 2010 - Design temperature 60 oC - Operating pressure < 5.0 Kg/Cm2(g) - Design pressure 5.0 Kg/Cm2(g) and Full Vacuum - Test pressure 7.5 Kg/Cm2(g) - Normal water flow 38,700 Cu.M/Hr. - Maximum water flow 41,910 Cu.M/Hr. - Installation position Vertical - Fluid handled Clarified Water - Empty weight 7,500 Kg. - Operating weight 23,360 Kg.



iv) Dimension - Shell ID x Thk Ø 2350mm x 14mm - Shell length (face to face) 2600 mm - Manhole Size 500 NB v) Material of construction - Shell Carbon Steel IS 2062 Gr. B

(Epoxy Coated) - Main flange Carbon Steel IS 2062 Gr. B / A105 / A148 Gr. 80-50W

(Epoxy Coated) - Internals SS316

3.4 WORM PLANETARY GEAR B21 (08PAF21AT001-M01 / 08PAF21AT002-M01) i) Make Bonfiglioli ii) Model 3 / VF 05L3 227 HC HS AF iii) Quantity 6 Nos. iv) Design temperature 60 oC v) Total reduction ratio 227 : 1 vi) Input speed 195 rpm vii) Input torque 16 Nm viii) Output speed 0.86 rpm ix) Output torque 2542 Nm

3.4 GEARED MOTOR DRIVE T21 (08PAF21AT001-M02 / 08PAF21AT002-M02) i) General - Manufacturer & Country of Origin Bonfiglioli , Italy - Model VF49 F1 7 P71 B14 B6 + BN71 B4 B14 - Equipment driven by motor Gear - motor type Squirrel cage induction motor, TEFC ii) Quantity 6 Nos. iii) Design Ambient Temperature 50°C



iv) Design & Performance Data - Frame Size BN 71B - Type of duty S1 - Type of Enclosure and method of cooling TEFC - Degree of protection IP 55 - Applicable standard to which motor

generally conforms IS 325 / IEC 34-1 - Type of mounting Horizontal Foot Mounted - Direction of rotation as viewed from De End Bi-Direction - Motor rating 0.37 kW - Rated voltage 415 V AC

- Permissible variation of a) Voltage + 10% b) Frequency + 5 % c) Combined voltage and frequency 10% Absolute - Minimum permissible Starting voltage 304 V AC - Rated speed 1370 rpm - Full load current at Rated voltage & freq. 1.04 A - Power factor at 100% load 0.77 - Efficiency at rated volt.&freq.-100% load 67% - Starting torque at Minimum permissible voltage 5.2 Nm - Rated torque 2.6 Nm - Vibration As per IS:12065 / IEC 34-14 - Noise level (dB) As per IS:12075 / IEC 34-9 v) Bearings - Type Life lubricated radial ball bearings - Recommended lubricant Life lubricated - Guaranteed life in hours 40,000 Hours vi) Constructional features - Stator winding - insulation class Class F with temperature raise limited

to Class B. - Temperature rise by resistance method

above the ambient of 50oC 70 oC (maximum) - Method of temperature measurement Resistance method - Stator winding connection Delta - Number of terminals brought out 6 - Type of terminal box for Stator leads Air insulated - Location for main terminal box Top - Total weight of motor 8.1 Kg. vii) GEAR BOX DETAILS - Model VF 49 F1 7 P71 B14 B6 - Type Planetary Gear Box - Total Reduction ratio 7:1 - Input speed 1370 rpm - Output speed 196 rpm - Input torque 2.6 Nm - Output torque 15.1 Nm



3.5 BALL VALVES i) Make Weir BDK ii) a. Size DN25 b. Tag Nos. N36, N37, N38, N39

(08PAF21AA301, 08PAF21AA302, 08PAF21AA303, 08PAF21AA304, 08PAF21AA305, 08PAF21AA306, 08PAF21AA307, 08PAF21AA308)

c. Type Manually Operated Full bore d. Quantity 24 Nos. iv) Liquid Handled Clarified Water v) Design temperature 60 oC vi) Design Pressure 5.0 Kg/cm2 (g) & Full Vacuum vii) Face to dimension 127 mm viii) Manufacturing Standard EN-ISO-17292 / BS - 5351 /

ANSI B16.34 / API 598 ix) Testing Standard BS-EN-12266 / BS 6755 Part-I / API 598 x) Material of construction a) Body &Tail Piece ASTM A 351 Gr.CF8M b) Ball ASTM A 276 Typ 316 c) Stem ASTM A 276 Typ 316 d) Seat PTFE xi) Type of end connection Flanged xii) Flange / Drilling Standard ANSI B16.5 Cl.150 , RF



3.6 BUTTERFLY VALVE M31 (08PAF21AA049 / 08PAF21AA050)

i) Make Intervalve ii) a. Size DN 300 b. Type Actuator Operated c. Quantity 6 Nos. iii) Liquid Handled Clarified Water iv) Design temperature 60 oC v) Design Pressure 5.0 Kg/cm2 (g) & Full Vacuum vi) Test Standard BS-EN-12266 / BS 6755 Part-I / API 598 vii) Material of construction - Body ASTM A 216 Gr.WCB - Disc ASTM A 351 Gr. CF8 (SS 304) - Shaft ASTM A 479 TYP 304 - Seat EPDM viii) Flange / Drilling Standard Wafer type for sandwich between

Flanges as per ANSI B16.5 Cl.150.

3.7 ACTUATOR FOR BUTTERFLY VALVE T31 (08PAF21AA503 / 08PAF21AA504) i) Make Auma, Germany ii) Quantity for 6 Systems 6 Nos. iii) Model No. SG 10.1-16 secs. / AM 01.1 iv) Application Valve Operation v) Type Part turn actuator vi) Torque range 250 - 600 Nm vii) Type of duty S2 - 15 Minutes viii) Enclosure IP 67 ix) Design ambient temperature 500C x) Torque limit switch 2 Nos.

(1 each in open and close position)



xi) End-of travel limit switch 4 Nos. (2 each in open and close position)

xii) No. of N.O. + N.C contacts provided for each limit switch 2 NO + 2NC contacts xiii) Switch Contact Rating a) at 240 V A.C 5 Amps b) at 220 V D.C 0.5 Amps xiv) Nominal output 0.16 kW xv) Rated voltage 415 V AC xvi) Rated frequency 50 Hz xvii) No of phases 3 Ph xviii) Admissible voltage fluctuation ± 10% xix) Admissible frequency fluctuation ± 5% xx) Admissible combined voltage and frequency fluctuation (absolute sum) 10% xx) Nominal current 0.60 A xxi) Motor Speed 2800 rpm xxii) Starting current 1.7 A xxiii) Current at maximum torque 0.9 A xxiv) Insulation class Class "F" with temp. rise limited to

Class "B" xxv) Power factor 0.67 xxvi) Space heater Voltage Power 24 V DC, 5 - 20 Watts



3.8 D.P. TRANSMITTER D01 (08PAF21CP181 / 08PAF21CP182) i) Type Remote Seal, HART Protocol

Compatible ii) Make Emerson Process Management iii) Model 3051CD-2-A-2-2-A-1-A-S2-B4-M5-Q4 +

1199DDB10ARFW21DAA1HJ iv) Quantity 6 Nos. v) Liquid Handled Clarified Water vi) Design temperature 50 oC vii) Design Pressure 5.0 Kg/cm2 (g) & Full Vacuum viii) Power Supply 16-48 V DC + 10% ix) Transmitter measurement Differential pressure across debris filter x) Measuring range 0 to 200 mbar xi) Transmitter output 4 - 20 mA DC signal xii) No. of wire 2 Nos. xiii) Housing material Polyurethane - covered Aluminium xiv) Material - Upper & Lower Housing SS 316 - Diaphragm (Remote Seal) SS 316L - Drain / Vent SS 316 xv) Mounting Surface Mounting xvi) Meter Digital meter, 0 to 200mbar xvii) Process connection 1" Flange as per ANSI B16.5 Cl.150 xviii) Zero and Span Drift + 0.015 % per deg C at maximum span

and 0.11 % per deg C at minimum span.

xix) Load limit (at 24 V DC) 500 Ohms



xx) Performance data - Accuracy + 0.075% of URL - Static and overpressure limits 254 Kg/cm2 - Stability + 0.125% of URL for 5 Years -Turn down ratio 100:1

xxi) Diagnostics Self indicating features provided xxii) Capillary Length 3 m xxiii) Electrical Connection Screw type terminals xxiv) Protection Class IP67 xxv) Cable Gland / Size Provided / 1/2" NPT

3.9 DP INDICATING SWITCH D03 (08PAF21CP251 / 08PAF21CP252)

i) Make General Instruments ii) Model IDPS-S-150-S4-S6-B-15-NT-M-18M-

0to200mbar-B ii) Medium Clarified Water iii) Quantity for 6 Systems 6 Nos. iv) Type Bellows v) Sensing Element material SS 316 vi) Casing Stainless Steel vi) Enclosure IP 66 viii) Range 0 to 200 mbar ix) Switch Type Snap Action x) Set points 1 Set point at 80 mbar (Adjustable) xi) Contact rating 5 Amps, 240 V AC, 220V DC, 0.5 AMP xii) Repeatability + 1% Span xiii) Accuracy +1.5% FSD xiv) Electrical Connection Screw Type Terminals



xv) Cable glands Provided / 1/2" NPT xvi) No. of Contacts 1 NO + 1 NC

3.10 D.P. INDICATOR E01, E02, E03, E04 (Common for Tube Cleaning System & Debris Filter)

i) Make Shinko, Japan ii) Model JIR – 301 - M iii) Quantity 12 Nos. iv) Type Analog to Digital v) Power supply 230V AC / 50 Hz vi) Measuring Range 0 to 100 mbar (TCS)

0 to 200 mbar (DF) vii) Installation type Flush Panel mounted viii) Measuring input 4 - 20 mA DC ix) Panel cutout dimension 92mm x 45mm x) Output signal - Type Digital - Number of control points Two (TCS), One (DF) xi) Control set at 40 mbar / 60 mbar (TCS) 80 mbar (DF) xii) Design ambient temperature 500C



3.11 INTERCONNECTING PIPING i) Make GEA BGR ii) Sizes 300 NB iii) Design temperature 60oC iv) Design pressure 5.0 Kg/cm2 (g) & Full Vacuum v) Test pressure 7.5 Kg/cm2 (g) vi) Material of Construction - Pipe Carbon Steel, IS 3589 - Flange Carbon Steel, A105 - Fittings Carbon Steel, A234 Gr. WPB vii) Connections - Type Flanged - Drilling standard ANSI B16.5 Cl.150 lbs., RF

3.12 CONTROL PANEL S01

(08PAH21GS001) (Common for Tube Cleaning System & Debris Filter)

i) Type PLC Based ii) Quantity 3 Nos. iii) Make of PLC ABB iv) Supply Voltage 2 x 240 V AC, 50 Hz (UPS)

1 x 240 V AC, 50 Hz (Non-UPS) v) Control Voltage 24V DC vi) Cables (Power & Control) PVC vii) Installation Position Vertical, Floor Mounted viii) Location Indoor ix) Protection Class IP 54 x) Cable Entry Bottom xi) Paint Shade Inside : Brilliant White Outside : RAL 7032



SECTION IV

PRECONDITION



4.1 STORAGE/PRESERVATION 4.1.1 EQUIPMENT & ACCESSORIES

The equipments, pipes and rods are to be kept on wood plank without touching the mud.

All pipes shall be preserved by a coat of preservative or paint. Plates shall be preserved by positioning vertically with proper supports in such a way they shall not get sagged or bent permanently.

All machined surfaces shall be preserved by rust preventive coating and covered by Polythene Sheet. Machined surfaces shall not be kept in such a way that damages can occur.

The equipment should be kept away from the flammable items.

Cover the finished goods with Tarpaulin/Polythene sheet to keep away from dust and rain. Then they should be packed in wooden box and stored in a group with tag nos. for easy identification. Cannibalization should be avoided.

4.1.2 ELECTRICAL & ELECTRONIC ITEMS

All Motors and actuators shall be away from areas where water or water droplet are likely to fall. Electrical and Electronic goods are to be covered with 3 types of packing like thermo coal, air bubbled sheet and polythene sheet, as applicable. INSTRUCTIONS DURING SHUTDOWN FOR MORE THAN 48 HOURS

Drain out the Circulating Water of Debris Filter.

Flush the Debris Filter with Fresh Water. Ensure that the Debris Filter is clean and dry.



4.2 SAFETY INSTRUCTIONS 4.2.1 GENERAL

Purpose To meet the accident free and also to achieve all the erection activities as per the guidance of safety instructions. Scope This is applicable to staff, skilled and unskilled manpower deputed during execution of erection & commissioning of on load condenser tube cleaning system.

Responsibilities It is every one responsibility to follow the safety instructions during erection work in order to meet the accident free day. Procedure Obtain the line clearance (Permit) from the engineer incharge before starting up the erection activities in case of retrofit. During erection of heavy activities, isolate the area of erection before starting up the work. Use the proper scaffolding and ladder whenever required to work in elevated locations. Use the safety belts to the manpower deputed to carry out the work in elevated locations. Follow the use if helmets, safety shoes in day-to-day activities inside the plant premises. Ensure that all the flammables and wastages are kept away from the working area. Ensure that the welders use appropriate shielding glass during welding activity. Ensure that the grinders use the goggles and apron during the grinding works. Ensure that the masks are worn during painting activity. Ensure that the load is lifted within the safe working load of the crane, rope, chain, D-shackle etc. The lifting angle of the rope or chain shall be within the safety limit.

4.2.2 ELECTRCITY

Check all the wire connections to prevent from looseness Leave all electrical connection to trained and qualified electrician Always use proper Lockout/Tagout procedures Always check your tools before use



All tools must be inspected & tagged by a qualified electrician The joints of the cable ends have to be properly insulated The power take up points of cables provided with proper socket pin arrangement. Do not use appliance with defective parts Always switch off the power supply after using electrical equipment. Replace/ report any defective electrical cords or equipment. Electrical cords must not create a tripping hazard. Investigate and report any unusual odors coming from electrical equipment or appliances. Turn off and unplug any electrical device before attempting to service or repair it. Do not overload electrical circuits.

4.2.3 PRESSURE

Our equipment is designed to the Design Pressure of 4 bar (g) and is safe for the given operating pressure condition.

4.2.4 TEMPERATURE

Our equipment can be safely operated up to the maximum temperature of 60ºC.

SUPPLIER’S SCOPE CUSTOMER’S SCOPE

Delivery of GEA-BGR component based on the design agreed in the contract and manufacture to an agreed quality programme.

Adequate pre-cleaning of the cooling water using bar screens, fine screens or similar type of Screens.

Detailed INSTALLATION PLAN (Drg. No.GI 3097 200 03 045) for installing the GEA-BGR components.

Correct installation of the GEA-BGR components

Proposals for the optimisation of the cooling water system.

Instructions for installing the GEA-

BGR components.

Final inspection of the assembly

For guidance, the supplier provides the customer with INSTALLATION PLAN (DRG. NO. GI 3097 200 03 045), contains detailed proposals and directives.



4.3 GENERAL INSTRUCTIONS

4.3.1 OPTIMISATION OF THE WATER CIRCULATION

Pre-Screening

The pre-screening must be sufficient, i.e., there must be no coarse debris larger than 10 mm which can enter the Debris Filter via the cooling water system. When the pre-screening in inadequate, partial blockage of the Debris Filter can occur and consequently result in unscheduled shutdown of the DEBRIS FILTER for manual cleaning.



SECTION V

REQUIRED TOOLS AND MATERIALS



5.1 REQUIRED TOOLS AND TACKLES – CHAIN PULLEY BLOCK 5 TON – 2 NOS.

– ROPES – 1 SET. FOR INTERNALS SHIFTING

– CHAIN PULLEY BLOCKS 3 TON – 2 NOS.

– WINCH HOOK – 1 NO.

– WIRE ROPES & ‘D’ SHACKELS – 2 SES.

– PNUMATIC BOLT LOOSENING / TIGHTENING – 1 SET.

– WITH THE REQUIRED SIZE SOCKETS

– SLEDGING RING SPANNER – 2 SETS.

[KNOCKING SPANNER]

– SLEDGE HAMMER – 2 NOS.

– GAS CUTTING SET – 1 SET.

– WELDING MACHINE – 1 SET. WITH CABLE & ACCESSORIES.

– TIG WELDING SET – 1 SET.

– DOUBLE END & RING SPANNER – 2 SETS [10MM TO 30x32] – ALLEN KEY SET [3MM TO 20MM] – 1 SET.

– CIRCLIP PLIER [6”] [INNER & OUTER] – 1 SET.

– SCREW DRIVER [8” & 12”] – 1 SET.

– FEELER GAUGE [6” Long] – 1 SET

– VERNIER CALIPER – 1 NO.

– PORTABLE HYDRAULIC JACK – 2 NOS. [1 TON & 2 TON]

– HAMMER 2LB / 4LB – 1 NO. EACH

– BRASS ROD ¾” x 10” – 1 NO.

– CENTER PUNCH – 1 NO.

– SS WIRE BRUSH – 2 NOS.

– GQ4 & FF2 GRINDING MACHINE – 1 SET EACH.

– TAP SET M4 – M20 WITH HANDLE – 1 SET EACH

– HACK SAW FRAME – 1 NO.

– HACK SAW FRAME WITH SPARE BLADE – 1 SET.

[FOR SS BOLT CUTTING]

– 24V DC TRANSFORMER & HAND LAMPS – 1 SET – EXHAUST FAN – 1 NO.



SECTION VI

INSTALLATION INSTRUCTION



6.1 DEBRIS FILTER

Installation is according to the P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045)

Any actuators used should only be attached after the general assembly, shortly before Commissioning. Adjustment of the limit switch depends on momentum and path is to be carried out according to the separate operating instructions for actuators.

6.2 DEBRIS DISCHARGE LINE

Piping arrangement and installation of debris discharge valve according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045).

Pipework should slope down to outlet.

Bowed and syphonic piping arrangements should be avoided

Connecting pipes should not be under stress.

Make sure that there are sufficient pipe supports.

While welding avoid excessive weld root penetration.

6.3 BALL VALVES

Position of installation according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045).

6.4 D.P. MEASURING SYSTEM

Assembly according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045).

Arrangement of measuring unit is recommended in the immediate vicinity of filter or in an easily accessible place.

Pipework to DP Transmitter should slope upwards.

Do not mix positive and negative terminals.

Note : Once the system has been assembled the Isolation Valves should be closed.



6.5 ISOLATION VALVES

Position of installation according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045).

Locate in dry area protected from dripping water.

Locate wherever possible, close to the system.

6.6 CONTROL PANEL

GENERAL Arrangement as per Control Panel Wiring Diagram Protect from direct sunlight when installed outdoors.

6.7 CABLING

The requirement of laying of power cables is to drive the motors and the requirement of laying control cables are for signal transmission and control power extension to various devices installed at field. Cables shall be supplied in cable drums. Before cutting the cables detailed measurements shall be taken in the field as per the field route convenience and as directed by the installation engineer. Cutting the cable for different length shall be such that wastage is minimum. Cables are to be routed as per routing given in the cable schedule. Whenever routing is not given in the drawing, cable shall be routed as per direction of erection engineer. The cable shall be routed away from oil and fire hazard area. Cable laid in cable trays shall be clamped at the interval of 1 meter by suitable clamps. Cable tag (Cable No/ Equipment destination / Description of the cable) should be clamped at both sides of the cables i.e. control panel end and Field end.



6.8 PRESERVATION MEASURES BEFORE COMMISSIONING

Once the installation is over as per the P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045) the following checks have to be carried out as a preventive measure for the entire system before commissioning.

- Ensure that all the fasteners of equipments such as Debris Filter & Inter Connecting

Piping have been fully tightened. - Make sure that the gaskets in between the flanges have been placed properly prior to

tightening of the fasteners. - The instruments such as Pressure Gauges & DP Transmitters should be covered

suitably to avoid any water dipping on them. - Make sure that cables of all the electrical drives such as Motors, Actuators have been

terminated properly on both field and panel end. - There should not be any moisture ingress to be allowed in the panel and the electrical

drives as it may lead to reduction in resistance value. - If the commissioning is not planned immediately all the drives to be properly covered

so that the equipments are protected from dust, water and other pollutions.



SECTION VII

SUPERVISION AND FINAL ASSEMBLY



7.1 COMPONENTS 7.1.1 Debris Filter, Worm Planetary Gear and Geared Motor Drive

Test Name Requirement Activity Result

1 Assembly Must be carried out according to P&I Diagram (GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045)

Check

2 Name Plate Must be complete Check

3 Geared Motor - Wiring

Motor must be connected according to the circuit diagram

Check

- Current setting Must be adjusted to the rated current according to the name plate

Check Adjustment with-in the range specified

- direction of rotation Must be clockwise viewed from the flow direction

Check by starting & stopping the rotation Motor

7.1.2 Debris Discharge Valve with Actuator



Check

2 Actuator - Wiring

Both motor and control signalling equipment must be connected according to the circuit diagram.

Check

- Current setting Must be adjusted to the rated current according to the name plate of the actuator

Check Adjustment with-in the range specified

- end position indicator (Control Cabinet)

In the position OPEN the corresponding lamp must light up.

Check

In the position CLOSE the corresponding lamp must light up.

Check



7.1.3 Debris Discharge Pipe



Check

7.2 D.P. MEASURING SYSTEM 7.2.1 D.P. TRANSMITTER



Check

2 Connection of positive and negative pipelines

Must be correct Check

3 Installation Perpendicular to the instrument

Check

Avoid Zero shift

Lowest level possible in respect to the Tube Cleaning System

4 Wiring Terminal & Loops for proper wiring

5 Voltage & Polarity 24V at the Terminals of the Transmitter & Indicator (loop-wired)

7.2.2 D.P. INDICATOR

TEST DESCRIPTION REQUIREMENT ACTIVITY RESULT

1 Power Supply 220 – 240V DC at the Terminals

Visual Check

2 Input 4 – 20 mA output from D.P. Transmitter

3 Wiring 24V DC positive to D.P. Transmitter positive. D.P. Transmitter negative to D.P. Indicator positive. 24V DC negative to D.P. Transmitter negative.

4 Set Value 80 mbar



7.2.3 D.P. Isolation Valves (Ball Valves)



Check

2 Operation

Must function without an excessive torque.

Check

7.3 CONTROL PANEL

Test Description Requirement Activity Result

1 Assembly Must be according to Control Panel Wiring Diagram

Check

2 Wiring (Supply lines from field to panel and from panel to field)

Must be done according to the Cable Routing and Cable Schedule

Check

3 Incoming Supply Switch

Switch on

Illuminated Push Button : Lamp Test

All lamps must light up Press and Check

4 MPCB (Motor Protection Circuit Breaker)

Range Setting is proper Check

7.4 TIMER SETTING

Tag No.

Name Requirement Activity Result

Flushing Timer 3 Min. (PLC Internal Timer)

Check

System Cycle Timer 4 Hours (PLC Internal Timer)

Check

DP High Sequence Lead Timer

30 Sec. (PLC Internal Timer)

Check

DP Fail Timer 10 Min. (PLC Internal Timer)

Check



SECTION VIII

COMMISSIONING



8.1 GENERAL INSTRUCTION

Before commissioning of the system the following controls of the electric installation are to be undertaken.

o Comparison of the electrical connections in the Control Panel, to the motor(s), and if

available, the monitoring system with the circuit diagram.

o Testing of the Motor overload relays.

o Check adjustment of the time relays.

Check whether the assembly of GEA BGR components and the laying of the pipes for Debris Discharge and Flush water have been carried out according to the documents / drawings.

Check the direction of rotation of extraction arm by starting the geared motor drive. The rotary arms can run when dry.



8.2 FILLING THE SYSTEM WITH WATER Pre-requirement : - All isolation valves are to be closed - Debris Discharge valve closed

Refer P&I DIAGRAM for Item Tag Nos.

Item Name Operation Effect

S01 Control Panel Is energized - main switch

Illuminated Push Button : Lamp Test

Switch ON press

All lamps should glow, if not change the defective Lamps

AUTOMATIC STOP Lamp AUTOMATICSTOP : ON AUTOMATIC START : OFF

B21, T21 Gear Motor Drive Lamp OFF : ON ON : OFF

M31, T31

Debris Discharge Valve

Lamp CLOSE : ON Lamp OPEN : OFF

OPEN THE MAIN INLET

Pre requirement for further operations : - the min. / max. quantity of cooling water does not fall below or exceed that given in the data sheet

N36, N37, N38, N39

D.P. Isolation Valves Open by hand D.P. Line is filled with water

THE TOTAL SYSTEM IS COMPLETELY FILLED WITH WATER



8.3 TRIAL OPERATION IN AUTOMATIC MODE Pre-requirement : - Isolation valves are open - The system is ready for Automatic Mode

Refer P&I DIAGRAM for Tag / KKS Nos.


S01 Control Panel Push Button

AUTOMATIC START Press

Lamp AUTOMATIC START : OFF

M31, T31 Debris Discharge Valve

Opens Lamp CLOSE : OFF Lamp OPEN : ON

B21, T21 Geared Motor Drive Starts to rotate after the Debris Discharge Valve is fully opened

Lamp ON : ON OFF : OFF

“Flushing Timer” picks up. When the timing is elapsed the closing operation is done

M31, T31


Closes Lamp OPEN : OFF Lamp CLOSE : ON

B21, T21 Geared Motor Drive Stops Lamp ON : OFF OFF : ON System stays in AUTOMATIC mode. Flushing can be introduced by PLC timer or DP Signal

8.3.1 DIFFERENTIAL PRESSURE MEASURING SYSTEM

Comment The fouling of the Filter is measured and displayed using the D.P. Measuring system. When the Filter is clean, the display must show less than 80 mbar. Turbulences caused by the operation can lead to different values being shown. In this case resetting to the relative 80 mbar positions must be undertaken. This is to be carried out according to the "Descriptions of Components" and should only be done by our Service Department. The sequence of operations can also be initiated in two other Auto Modes of operations

i) By the Timer, whenever its set time is elapsed. ii) Whenever the DP across the Debris Filter goes above the set value.



8.4 TRIAL OPERATION IN AUTOMATIC MODE (SHUT DOWN) Pre-requirement : - System is in “AUTOMATIC ON” position as specified under 8.2 (Before the flushing

timer is elapsed)

Refer P&I DIAGRAM for Tag Nos.


S01 Control Panel

Push Button AUTOMATIC STOP

Press

Lamp AUTOMATIC START : OFF AUTOMATIC STOP : ON

M31, T31


Closes Lamp OPEN : OFF Lamp CLOSE : ON

B21, T21 Geared Motor Drive

Stops Lamp OFF : ON ON : OFF

SYSTEM IS OUT OF SERVICE

CAUTION : System must be in operation when main cooling water is running.

For complete SHUT-DOWN close DP isolation valves N36, N37, N38, N39

Turn MAIN SWITCH at Control Panel to position OFF. When the system is to be kept “OUT OF SERVICE” for a longer time the Cooling Water “must” be drained off from all the equipments.



SECTION IX

OPERATIONS



9.1 SYSTEM OPERATION This write up covers the sequence of operations for Debris Filter in the “AUTO” mode and “MANUAL” mode. 9.1.1 SALIENT FEATURES

i) The Control logic is set out to cater to the operational requirements of Debris Filter under

all conditions.

ii) Debris Filter functions in two modes.

a. LOCAL AUTO MODE - Operation in LOCAL AUTO can be selected by turning the function selector switch in the Control Panel to LOCAL AUTO.

b. MANUAL MODE - Operation in MANUAL can be selected by turning the function selector switch in the Control panel to MANUAL.

iii) Electric actuators are provided with end travel limit and collective fault switches.

iv) Indication and audible alarm, in the form of feedback signal, has been provided in the

panel for all failure signals.

v) 4-20mA Analog Signal from the Differential Pressure Transmitter (08PAF21CP181) is used for DP measurement across Debris Filter. And DP Indicator with switch (08PAF21CP251) is used as backup for the DP set point.

vi) Ready to start lamp has to illuminate only when all the electrical drives are in “HEALTHY” condition. The “HEALTHY” condition is defined as a condition when all “FAIL”, “DP high” and “DP fail” indications are in “OFF” condition. These conditions and the availability of the “START PERMISSIVE (Any one of the main CW pumps on feedback AND 'Supply and return line MOV (08PAB21AA003 and 08PAB21AA006 or 08PAB21AA004 and 08PAB21AA005) open feedback signals from the DCS and DP minimum set signal from DPT across the Debris Filter)” signal will lead to switch “ON” the “READY TO START” indication. In case the “START PERMIT” signal is cut off during normal operation of DF, the system is brought to stop condition as detailed under “NORMAL AUTOMATIC STOP”.

vii) Summary failure indication is for failures in the power circuitry and individual drives. Sequence failure indication is for run time failure of actuators during the operation of the system.

viii) When the system is in “AUTOMATIC” Mode it will not respond for any manual pressing of individual Illuminated Push Button.

ix) The illuminated pushbutton will blink when the electric actuator operated valves move from one status to another status. The corresponding illuminated pushbutton will glow steadily when end travel limit switch is reached.

x) If Power fails, in any stage of the logic sequence - all equipment will come to initial position when power is restored, and manual interference is required for restarting.



9.1.3 MANUAL MODE The system can be operated by activating individual drives once the Selector Switch is turned to MANUAL. This mode is used predominantly for testing & commissioning purposes.

Note : Please note down there will be no interlocking of equipments in manual mode and any equipment can be operated at any stage.

9.1.4 AUTOMATIC MODE

INITIAL CONDITIONS i) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) should be in CLOSE

position. ii) GEARED MOTOR DRIVE (08PAF21AT001-M02) should be in OFF position iii) All FAIL indication in Control panel should be in OFF position. iv) Any one of the main CW pumps (2x50%) on feedback AND 'Supply and return line MOV

(08PAB21AA003 and 08PAB21AA006 or 08PAB21AA004 and 08PAB21AA005) open feedback signals' and DP minimum set signal (START PERMISSIVE) signal should be available.

v) Manual valves 08PAF21AA301, 08PAF21AA302, 08PAF21AA303 & 08PAF21AA304 should be in open position.

vi) If the INITIAL CONDITIONS are satisfied, the operation of the system can be executed in the following sequence. In case the initial conditions are not met, then the relevant equipment has to be brought manually to the required state to meet the INITIAL CONDITIONS (provided there are no FAIL indications)

vii) Select AUTO/MANUAL function to “LOCAL AUTO” position. viii) “SYSTEM AUTOMATIC STOP” indication will be illuminated ix) READY TO START Indication should be illuminated x) Press the "SYSTEM AUTOMATIC START" illuminated pushbutton in MIMIC to start the

system in "AUTO" mode.

AUTO START SEQUENCE i) Press the “AUTO START” illuminated pushbutton the following operations take place in

sequence. “AUTO START” illuminated pushbutton will start to blink and the illuminated push button AUTO STOP will be switched OFF.

ii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will open. iii) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched ON. iv) Now the system is in operation position and FLUSHING TIMER will pick up for 3

minutes (PLC internal timer) v) Once the flushing time of 3 minutes is elapsed, Flushing Operation will be stopped. vi) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched OFF. vii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED. viii) System cycle timer will be energized. ix) The system will restart for next cleaning as per the above sequence after the preset system

cycle timer elapses.



DEBRIS FILTER OPERATION BY D.P. MODE When the differential pressure across the Filter exceeds 80 mBar (Adjustable depending on the site condition), the DP HIGH SEQUENCE LEAD TIMER (30 seconds) will be energized to ensure that the increase in differential pressure is not due to any momentary surge. After a time delay of 30 seconds, if the DP is still higher than 80 mBar, the flushing sequence will commence. System Cycle timer will be de-energized and the flushing sequence will be started as indicated below. During the flushing time if the DP is reduced the sequence will not be disturbed up to the end of the sequence of operation. i) “D.P. HIGH” Indication will be illuminated. ii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be opened. iii) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched ON. iv) Now the system is in operation condition and FLUSHING TIMER will pick up for 3

minutes (PLC- internal timer). v) Once the flushing time of 3 minutes is elapsed, check the differential pressure across the

Filter. vi) If DP is above 80 mBar, then DP FAIL TIMER will pick up for 10 minutes (PLC – internal

timer) and the Flushing operation will be continued. vii) Once the DP fail time of 10 minutes is elapsed, Check the differential pressure across the

Filter is still above 80 mBar. viii) If DP is still higher than 80 mBar, the flushing operation continues, the DP FAIL indication

will blink, HOOTER will be actuated. Press the “FAULT ACCEPT” Push Button to switch OFF hooter and “DP FAILURE” indication will be illuminated steadily. Now the manual intervention is required to ascertain the cause and rectify manually. Once DP is reduced to less than 80 mBar press the “FAULT RESET” Push Button “DP FAILURE” indication will be switched OFF.

ix) If the DP is lesser than 80 mBar, system cycle timer will be started. And GEARED MOTOR DRIVE (08PAF21AT001-M02) is switched OFF. DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED.

DEBRIS FILTER OPERATION IN TIMER MODE When the system is in “AUTO” mode and immediately after the completion of flushing cycle, the system cycle time is energized for 4 hours (“System Cycle Timer” – PLC internal timer). Once the SYSTEM CYCLE TIMER is elapsed, the debris flushing sequence starts with the following sequence of operations: i) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be opened. ii) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched ON. iii) Now the system is in operation position and FLUSHING TIMER will pick up for 3 minutes

(PLC- internal timer). iv) Once the flushing time of 3 minutes is elapsed, Flushing Operation will be stopped. v) GEARED MOTOR DRIVE (08PAF21AT001-M02) is switched OFF. vi) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED. vii) System cycle timer will be started for 4 hours.



AUTOMATIC STOP SEQUENCE This will take place only if the system is in AUTO MODE and the system in flushing operation. This is initiated when the AUTO STOP illuminated Push Button is pressed or Flushing timer elapses or “START PERMISSIVE” feedback cut off or any fail comes, the following sequence of operation will take place. i) GEARED MOTOR DRIVE (08PAF21AT001-M02) is switched OFF. ii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED. iii) Auto start indication will be switched off and Auto Stop indication will be illuminated. 9.1.5 SETTINGS OF TIMERS (PLC Internal Timers) i) Flushing Timer : 3 Minutes (PLC Internal Timer) ii) System cycle Timer : 4 Hours (PLC Internal Timer) iii) DP high Sequence lead timer : 30 Sec. (PLC Internal Timer) iv) DP fail timer : 10 Minutes (PLC Internal Timer) 9.1.7 CAUSES FOR FAIL a. BY MPCB FAILURE If Motors/Valves are overloaded, the corresponding MPCB will trip and FAIL Indication will come in Control panel MIMIC. Press FAULT ACCEPT Push Button so that lamp will glow steadily. After the equipment is checked for the healthiness, reset the MPCB. Press FAULT RESET Push Button, so that FAIL Indication goes OFF. b. BY COLLECTIVE FAULT SWITCH If collective fault switch is engaged in either position of the Actuator, corresponding Actuator FAIL Indication will come in Control panel MIMIC and the Power Contactor will de-energize. Press FAULT ACCEPT Push Button, Indication will glow steadily. After actuator comes to free movement, press FAULT RESET Push Button FAIL indication goes OFF. c. RUN TIME ERROR During running period, if time taken by the Actuator is over headed, respective Power Contactor will be de-energized by PLC Internal Timer called runtime error timer and corresponding FAIL Indication will blink.

ACTUAL SETTING RUNNING PERIOD FOR FAIL

1. Debris Discharge valve Actuator 16 Sec. 20 Sec. Press FAULT ACCEPT Push Button, FAIL Indication will glow steadily and after the end travel limit received, Press FAULT RESET Push Button, FAIL Indication goes OFF.



d. OPERATION DURING FAIL OF ANY ONE OF THE EQUIPMENT If individual equipment fails to operate during the operation of the sequence logic – all the equipments except the failed one will go to initial position and operator must restart the system after resolving the problem of failed equipment. e. SUMMARY FAILURE INDICATION During operation of the equipment, if problem in the Power Circuit i.e. problem in Over Load Relay and Main Circuit Breaker, supply to the particular equipment will cut off. The corresponding FAIL Indication will glow along with the SUMMARY FAILURE Indication. f. SEQUENCE FAILURE INDICATION During operation of the equipment, if problem in the Control Circuit i.e. runtime error, supply to the particular equipment will cut off. The corresponding FAIL Indication will glow along with the SEQUENCE FAILURE indication. g. RED, YELLOW, BLUE LAMP INDICATION If the Main incoming source available the RED, YELLOW and BLUE incoming indications lamps will glow. h. LAMP TEST PUSH BUTTON If the lamp test is Push Button is pressed all lamps in the control panel will glow to check their healthiness. i. FAULT ACCEPT AND FAULT RESET PUSH BUTTON The SEQUENCE / SUMMARY FAIL Indication will blink along with the equipment FAIL Indication for fault condition, Alarm will be switched ON. Press FAULT ACCEPT Push Button, SEQUENCE / SUMMARY FAIL and corresponding equipment FAIL Indication will glow steadily and Alarm will be switched OFF. After rectification of the fault, press FAULT RESET Push Button, SEQUENCE / SUMMARY FAIL Indication and corresponding equipment FAIL Indication goes OFF.



SECTION X

SERVICE & MAINTENANCE



10.1 GENERAL MAINTENANCE

Activity Frequency

Check the tightness of all fixing bolts of filter internals Yearly

Check alignment of gear sealing, rotating arms and debris outlet pipe Yearly

Check condition of sacrificial anodes and if found corroded excessively arrange for replacement (if provided)

Yearly

Lubricate gear box Yearly

Check condition of mechanical seal of water pumps and replace if required

Half Yearly & Yearly

Check and replace all rubber items and seals inside the filter Yearly

Grease Drive shaft coupling Yearly

Check condition of pump rubber coupling and replace if found cracked

Quarterly, Half Yearly and Yearly

Check condition of valve seats and replace if found leaking Half Yearly and Yearly

Check and replace Panel indicating lamp bulbs if found blow off Half Yearly and Yearly

10.2 MAINTENANCE OF DEBRIS FILTER

Item Name Check Maintenance

C11 Debris Filter including flange connection

Visually Check outside for leakiness from time to time

None

B21, T21 Geared Drive with Motor

None After approx. two hundred (200) operating Hrs. check that the fastening bolts fastened properly and tighten if necessary, change grease after 3 - 5 years.

M31, T31


Visually check outside for tightness from time to time

None

- actuator with normal use of actuator, the grease in mechanical lock adjustment device and the moving parts like Valve adaptor and the coupling are lubricated for every 3 years. When subjected to heavier services (duty) the intervals between changes should be correspondingly shorter.



Item Name Check Maintenance

N36, N37, N38, N39

DP Isolation Valves

Visually check outside for leak tightness from time to time

None

D01

D.P. Measuring System

Visually check outside for leak tightness from time to time

None

S01

Control Panel - button : Lamp Test

Press from time to time

all lamps must light up, replace those which do not

Operations are automatically monitored and displayed.

None

- Faults are automatically monitored and displayed.

None

- Current Setting Check from time to time that it functions



SECTION XI

LUBRICATION



11.1 PLANETARY WORM GEAR BOX

MAKE BONFIGLIOLI, ITALY

TYPE 3 / VF 05 L3 227 HC HS AF

TYPE OF LUBRICATION SYNTHETIC OIL

LUBRICATION MAKE SHELL / MOBIL

GRADE TIVELA S 220 / SHC XMP 220

TEMPERATURE -20°C TO +60°C

INITIAL CHARGE QUANTITY Factory Filled

REFILLING PERIOD

Initial oil change after 150 – 200 hours. Subsequent oil change after every 2000 - 3000 hours operation. Alternatively change oil once a year.

REFILLING QUANTITY Planetary Gear - 2.10 LITRES Worm Gear - 0.43 (Life Lubricated)

SYNTHETIC & MINERAL LUBRICANTS SHOULD NOT BE MIXED



11.2 GEARED MOTOR DRIVE

MAKE BONFIGLIOLI, ITALY

TYPE VF 49 F1 7 P71 B14 B6 + BN71 B4 B14

TYPE OF LUBRICATION SYNTHETIC OIL

LUBRICATION MAKE SHELL / MOBIL

GRADE TIVELA S 320 / GLYGOYLE 320

TEMPERATURE -20°C TO +60°C

INITIAL CHARGE QUANTITY 0.12 Lit (Factory Filled - Life Lubricated)

REFILLING PERIOD SELDOM REQUIRED

REFILLING QUANTITY SELDOM REQUIRED

SYNTHETIC & MINERAL LUBRICANTS SHOULD NOT BE MIXED



11.3 ACTUATOR FOR DEBRIS DISCHARGE VALVE

MAKE AUMA, GERMANY

TYPE SG 07.1-16 secs

TYPE OF LUBRICATION GREASE

LUBRICATION MAKE SHELL / MOBIL / IOCL

GRADE ALVANIA EP(LF) 00/ MOBILPLEX EP0/ Servogem EP0

TEMPERATURE -25 Deg.C TO +80 Deg.C

INITIAL CHARGE QUANTITY FACTORY FILLED

REFILLING PERIOD SELDOM REQUIRED

REFILLING QUANTITY SELDOM REQUIRED

USE ONLY SUITABLE GREASE ! DO NOT MIX DIFFERENT GREASES !



SECTION XII

TROUBLESHOOTING



12.1 DEBRIS FILTER


T21 Geared drive for rotary system Control Panel - ROTATION MOTOR - overload relay

Press

Not working Hooter alarms lamp FAIL : ON has sprung out

Push Button : FAULT ACCEPT

Press ALARM OFF

Press ALARM OFF

Rectify Fault

Push Button : FAULT RESET

Press LAMP FAIL : OFF

LAMP SUMMARY FAIL : OFF

FAULTFINDING :

Item Fault Cause Repair

T21 Motor Overload (trips overload relay)

motor overload relay is set too low

Adjust to rated current

Motor is blocked Checked the gear drive Move freely : correct


T31 Actuator for Debris Outlet Valve

Not working

Control Cabinet - Debris Outlet Valve

Hooter alarms Lamp Fail : ON

- Overload Relay Has sprung out


Press ALARM OFF

Rectify fault


Press LAMP FAIL : OFF LAMP SUMMARY FAIL : OFF

FAULTFINDING :


T31 Motor Overload motor overload relay is set too low

Adjust to rated current

Motor is blocked Checked the - actuator Move freely : correct possible faults as per special operating instructions




S01 Control Panel Hooter alarms

D.P. Debris Filter Lamp ”DP FAIL HIGH” : ON


Press AUDIO ALARM : OFF

Push Button : RESET DP FAIL

Press Lamp ”DP FAIL HIGH” : ON


Press LAMP FAIL : OFF LAMP SUMMARY FAIL : OFF

FAULT FINDING :


E02 / E04

Filter overload Limit value is set too low

Adjust to related value

C11 Filter basket of debris filter has not been cleaned in spite of flushing

Too much debris enters the filter or coarse debris has caused clogging in debris discharge line

Let filter flush several times under supervising delta-p display

12.2 BLOCKED TUBES


D.P. Measuring System Impulse lines (Both Positive & Negative)

is Blocked is Blocked

Transducer and Measuring lines are Flushed and their operation again checked

If the failure indicator again lights up carry out FAULT FINDING :


Negative or Positive lines Blocked

Fouling Manual Cleaning of Blocked pipes

Isolating Valve is closed

Open



12.3 D.P. TRANSMITTER

FAILURE REMEDY

Transmitter milliamp reading is zero

Verify power is applied to signal terminals

Check power wires for reversed polarity

Verify terminal voltage is 10.5 to 42.4 V dc

Check for open diode across test terminal

Transmitter Not Communicating with HART Communicator

Verify the output is between 4 and 20 mA or saturation levels

Verify clean DC Power to transmitter (Max AC noise 0.2 volts peak to peak)

Check loop resistance, 250 Ω minimum (PS voltage -transmitter voltage/loop current)

Check if unit is addressed properly

Transmitter milliamp reading is low or high

Verify applied pressure

Verify 4 and 20 mA range points

Verify output is not in alarm condition

Verify if 4 – 20 mA output trim is required

Transmitter will not respond to changes in applied pressure

Check test equipment

Check impulse piping or manifold for blockage

Verify applied pressure is between the 4 and 20 mA set points

Verify output is not in alarm condition

Verify transmitter is not in Loop Test mode

Digital Pressure Variable reading is low or high

Check test equipment (verify accuracy)

Check impulse piping for blockage or low fill in wet leg

Verify transmitter is calibrated properly

Verify pressure calculations for application

Digital Pressure Variable reading is erratic

Check application for faulty equipment in pressure line

Verify transmitter is not reacting directly to equipment turning on/off

Verify damping is set properly for application

Milliamp reading is erratic

Verify power source to transmitter has adequate voltage and current

Check for external electrical interference

Verify transmitter is properly grounded

Verify shield for twisted pair is only grounded at one end



SECTION XIII

DOCUMENTATION



13.1 BALL VALVES

This write up contains instructions for installation, operation and maintenance of Ball Valves.



13.1.1 PRIOR TO INSTALLATION a) The valve and its accessories are to be checked for any damage during transportation. b) Any wrapping and protection applied should be left in place until the valve is installed. c) If the valves are left exposed they should be protected against entry of foreign material in

the valve parts. d) If the valves are stored for a long time, then before installing all valves should be cleaned

with lubricants. It is advised to store the valve in full open position. e) The pipe should be flushed clean, before mounting the valve. Impurities such as sand and

parts of welding electrodes could damage the ball surface and the seats. f) Valves stored for long time should be hydraulic tested before installation. g) If drain tapping or by passing is to be done, body should be drilled on the bosses provided.

13.1.2 INSTALLATION a) The flange gaskets & fasteners must be suitable for the operating conditions. b) The Standard Valves can be mounted in any convenient position, preferably with access to

packing gland nuts, actuators etc. The mounting of the valve with the stem downwards must be avoided because in case of possible leakage in the packing the flowing fluid would run over the actuator. Mounting of valve with the stem horizontal is normally preferred.

c) The pipe misalignment should not be corrected by means of flange bolts. d) Valves should not carry the weight of pipeline to avoid distortion and jamming. e) Valve Supporting :

It is normal to have valve supported simply by its connections and proper supporting of the pipe line. This minimizes strain on the valve caused by stress in the pipeline. The valve can be supported by its body with pipe clamps and supports. The supporting structure should not be fastened to flange bolts or actuators.

f) The gland packing should be tightened uniformly before installing and after the trial

operation of the valve.

g) Proper gasket should be inserted between the mating flanges. The flange bolt holes should be aligned and held in place.

h) The nuts on back side of the valve flange should be held first and then the bolts should be

inserted. i) All the bolts should be finger tightened first.



j) Torque wrench must be used to tighten the bolts. k) The stem packing may leak after a long storing time. The packing must be tightened

uniformly before installing the valve. l) The pipe line must be flushed carefully once more when the valve are mounted to remove

all the possible impurities. Before flushing the valve should be kept open fully. m) The packing should be re-tightened if necessary until all leakage has stopped.

13.1.3 OPERATION AND MAINTENANCE

a) Valves should be opened and closed slowly to avoid hammering effect on the valve and pipeline.

b) Valve should be "fully opened" or "fully closed" so that wire drawing effect can be reduced. c) It is advisable to use the valves only for on-off services. The use of valve for throttling

services should be avoided. d) If the valve leaks, extra leverage or extra force should not be used on the stem. The valve

must be removed and inspected to locate the cause of leak. e) After a long service life, the seats can be interchanged if required.

f) Normally the ball valve needs no regular maintenance. In case if leak occurs the stem

packing should be tightened. g) When replacing the packing, the valve should not be under pressure. Actuator need to be

removed. After loosening the gland nut and lifting up the gland the packing can be removed.

h) The body end cover studs and nuts should not be over tightened to avoid the body seal

leak. Instead body seal should be removed and replaced by new one.

13.1.4 DIS-ASSEMBLY

It may be necessary to disassemble the valve for maintenance because of following reasons:

o Valve leaks in close condition. o Ball is stuck. o Inside of valve needs cleaning.

DIS-ASSEMBLY FROM PIPE LINE

o The line should be depressurised and the system fluid must be drained. The valve should be cycled several times to relieve any pressure inside the valves.

o The valve should be kept in open position, unfastened and placed on a level surface.



DIS-ASSEMBLING THE VALVE

o The valve must be flushed to remove the residuals in the valve.

o The valve must be supported on a platform.

o The adaptor should be removed and split nut screw is unscrewed.

o The check nut, gland and bracket must be removed if the valves are driven by actuator. o The lever nut, lever, gland nut, gland must be removed if the valves are manually

operated.

o The body end connection should be unscrewed and the body should be separated from the end pieces.

o The body tailpiece connection should be unscrewed and the tail piece should be

separated from the body. o The disassembled parts must be placed on clean wood or cardboard. The ball should

not be kept on cement or metal surfaces. o The seat rings and body seal should be taken out. Body seal may be replaced during re-

assembly.

o The valve should be kept closed and the ball must be removed.

o The stem is then pushed into the body cavity and removed through the end port. The stem washer and stem seal can now be removed.

o All dirty parts are to be cleaned carefully. If necessary suitable solvents should be used. o The sealing surface of the ball or the seat is to be checked for any damage. If only the

seats are damaged, the seats must be replaced. Minor scratches or flashes on the ball surface or in the seats can be smoothened with fine grinding cloth.

o The condition of the stem seals and the stem washer should be checked.

13.1.5 REASSEMBLY

Reassembly can be done exactly in the reverse order of dis-assembly.



13.2 ACTUATOR FOR DEBRIS DISCHARGE VALVE (SG 07.1)

This write up contains the general operation instructions of the Actuator for Ball Valve.



13.2.1 TECHNICAL DATA

F e a t u r e s a n d f u n c t i o n s

Type of duty 1) SG: Short time duty S2 - 15 min SGR: Intermittent duty S4 - 25 %

Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34 (SG and SGR)

Options: 1-phase AC motor (SG only) DC shunt motor (SG only)

Insulation class Standard: F, tropicalized Option: H, tropicalized (3-phase AC motors only)

Motor protection Standard: Thermoswitches (NC) (DC motors without motor protection) Option: PTC thermistors (according to DIN 44082)

Self-locking Yes

Swing angle Standard: 80° to 110° adjustable between min. and max. value. Options: 30°–40°, 40°–55°, 55°–80°, 110°–160°, 160°– 230° or 230°– 320°

Limit switching Counter gear mechanism for end positions CLOSED and OPEN Standard: Single switch (1 NC and 1 NO) for each end position Options: Tandem switch (2 NC and 2 NO) for each end position,

switches galvanically isolated Triple switch (3 NC and 3 NO) for each end position,

switches galvanically isolated Intermediate position switch (DUO limit switching),

available for any intermediate position

Torque switching Infinitely adjustable torque switching for direction OPEN and CLOSE Standard: Single switch (1 NC and 1 NO) for each direction Options: Tandem switch (2 NC and 2 NO) for each direction, switches

galvanically isolated

Position feedback signal, analogue (options)

Potentiometer or 0/4 – 20 mA (RWG) For further details, see separate data sheet

Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED

Running indication (option) Blinker transmitter

Heater in switch compartment Standard: Resistance type heater with 5 W, 24 V DC Options: Self-regulating PTC heater, 5 – 20 W 24 – 48 V AC/DC, 110 – 250 V AC/DC or 380 – 400 V AC

Motor heater (option) 12.5 W

Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during electrical operation. Option: Handwheel lockable

Connection to controls AUMA plug/ socket connector with screw type connection

Splined coupling for connection to the valve shaft

Standard: Coupling without bore Options: Machined coupling with bore and keyway, square bore or

bore with two-flats according to EN ISO 5211

Valve attachment Dimensions according to EN ISO 5211

Voltage supply Refer to name plate of actuator controls

External supply of the electronics 24 V DC + 20 % / – 15 %,



(option) Current consumption: Basic version approx. 200 mA, with options up to 500 Ma

Switchgear Standard: Reversing contactors2) (mechanically and electrically interlocked) for motor power up to 1.5 kW

Options: Thyristor unit (recommended for modulating actuators) for motor power up to 1.5 kW, 500 V AC with internal fuses

Control Standard: Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator, with one common), current consumption: approx. 10 mA per input

Observe min. duration of impulse for modulating actuators

Option: Control inputs 220 V AC, OPEN - STOP - CLOSE (via opto-isolator, with one common), current consumption: approx. 15 mA per input

Output signals Standard: 5 output relays with gold-plated contacts: 4 potential-free NO contacts with one common: max. 250 V AC, 0.5 A (resistive load) Standard configuration: End position OPEN, end position CLOSED, selector switch REMOTE, selector switch LOCAL 1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load) for collective fault signal Standard configuration: Torque fault, phase failure, motor protection tripped

Option: Signals in connection with positioner: End position OPEN, end position CLOSED (requires tandem switch within actuator) Selector switch REMOTE, selector switch LOCAL via selector switch 2nd level 1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load) for collective fault signal Standard configuration: Torque fault, phase failure, motor protection tripped

Voltage output Standard: Auxiliary voltage 24 V DC, max. 50 mA for supply of the control inputs, galvanically isolated from internal voltage supply

Option: Auxiliary voltage 115 V AC, max. 30 mA for supply of the control inputs,3) galvanically isolated from internal voltage supply

Local controls Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all three positions)

Push buttons OPEN - STOP - CLOSE

3 indication lights: End position CLOSED (yellow), collective fault signal (red), end position OPEN (green)

Option: Protection cover, lockable

Functions Standard: Switch-off mode adjustable Limit or torque seating for end position OPEN and end position CLOSED

Overload protection against excessive torques over the whole travel

Excessive torque (torque fault) can be excluded by collective fault signal



Phase failure monitoring with automatic phase correction

Push-to-run operation or self-retaining in REMOTE

Push-to-run operation or self-retaining in LOCAL

Blinker transmitter signal can be switched on or off by actuator (option)

Options: Positioner4) Nominal position value via analogue input E1 = 0/4 – 20 mA Adjustable behaviour on loss of signal Adjustable sensitivity (dead band) and pause time Split Range operation

Motor protection evaluation Standard: Monitoring of the motor temperature in combination with thermoswitches in the actuator motor

Options: Additional thermal overload relay in the controls

PTC tripping device in combination with PTC thermistors in the actuator motor

Electrical connection Standard: AUMA plug/ socket connector with screw type connection

Threads for cable glands Standard: Options:

Metric threads Pg-threads, NPT-threads, G-threads

Wiring diagram Wiring diagram according to commission number included in delivery

Further options for version with RWG in the actuator

Position feedback (Option)

Analogue output E2 = 0/4 – 20 mA (load max. 500 Ω)

Service conditions

Enclosure protection according to EN 60 5295)

Standard: IP 67 Options: IP 68 IP 67-DS (Double Sealed) IP 68-DS (Double Sealed) (Double Sealed: electrical connection compartment additionally sealed against interior)

Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plants with a low pollutant concentration

Options: KS Suitable for installation in occasionally or

permanently aggressive atmosphere with a moderate pollutant concentration (e.g. in wastewater treatment plants, chemical industry)

KX Suitable for installation in extremely aggressive atmospherewith high humidity and high pollutant concentration

KX-G same as KX, however aluminium-free version (outer parts)

Finish coating Standard: Two-component iron-mica combination

Standard colour Standard: Grey (DB 702, similar to RAL 9007) Option: Other colours are possible on request

Ambient temperature Standard SG: – 25 °C to + 70 °C Standard SGR: – 25 °C to + 60 °C (with 3-phase AC motor) Options: – 40 °C to + 60 °C, low temperature incl. heating system – 50 °C to + 60 °C, extreme low temperature incl. heating

system (SG with 3-phase AC current only)



Lifetime SG 05.1/ SG 07.1: 20,000 operating cycles (OPEN - CLOSE - OPEN) for 90° SG 10.1: 15,000 operating cycles (OPEN - CLOSE - OPEN) for 90° SG 12.1: 10,000 operating cycles (OPEN - CLOSE - OPEN) for 90° SGR 05.1 – 12.16): min. 2.5 million operations (control steps)

Accessories

Wall bracket (7) AUMA MATIC mounted separately from the actuator, including plug/ socket connector. Connecting cables on request. Recommended for high ambient temperatures, difficult access, or in case of heavy vibrations during service.

Other information

EU Directives Electromagnetic Compatibility (EMC): (89/336/EEC) Low Voltage Directive: (73/23/EEC) Machinery Directive: (98/37/EC)

Reference documents Product description “Electric part-turn actuators SG” Product description, “Actuator controls AUMA MATIC” Dimension sheets SG/ SGR “with integral controls AUMA MATIC” Technical data SG/ SGR Technical data AM 01.1 Electrical data SG/ SGR

1) Based on 20 °C ambient temperature and at an average load with running torque according to Technical data SG or SGR 2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles is to be

expected, thyristor units with virtually unlimited lifetime should be used 3) Not possible in combination with PTC tripping device 4) Requires position transmitter in actuator 5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended.

Additionally, for enclosure protection IP 68, we recommend to use the double sealed terminal compartment DS. For special motors, the enclosure protection according to the name plate applies

6) The lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process

7) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an RWG has to be used in the actuator

13.2.2 ADDITIONAL INFORMATION TO THE WIRING DIAGRAM Information A A running indication is possible if blinker transmitter (S5) is installed

(opening and closing of contacts). Direction CLOSE: Connections XK 6 - XK 7 Direction OPEN: Connections XK 6 - XK 8 Contacts remain closed in end position. When connected to an external PLC, the blinking signal can be switched off via the DIP-switches (table 6)

Information B The type of seating in the end positions is determined by the valve

manufacturer. The setting is done at the programming switches S1-2 and S3-2. The tripping of a torque switch in an intermediate position switches off the actuator and causes a fault signal. The limit switches serve for signalisation when switching off by torque seating. They need to be set so that the appropriate switch is tripped shortly before reaching the end position. If the torque switch trips before the limit switch, the actuator is switched off and a fault signal is generated. For further programming possibilities, e.g. self-retaining in operation mode REMOTE, see table 6.



Information D The following faults are registered and can be transmitted to the control

room as a potential-free collective fault signal: Power failure Phase failure Motor protection tripped Torque switch tripped in mid-travel.

This signal can be switched off on the logic board, see table 6. Information E Input signals according to DIN 19 240.

The nominal operation current of inputs XK 2, XK 3, and XK 4 amounts to 10 – 15 mA. If the internal voltage 24 V DC is used for remote control, it must only be connected via potential-free contacts.

Information F In case of wrong phase sequence, the running direction is automatically adjusted. In case of a phase failure, the actuator stops. The fault is indicated at LED V14 on the interface board. For collective fault signal, see information D.

Information G Potential-free contacts are available for signals. The internal control voltage

(XK 11 / + 24 V and XK 5 / – 24V) must not be used for external lamps, relays

etc. 13.2.3 STORAGE

In order to avoid damages due to unappropriate storage, following points should be observed :

Store in well ventilated, dry rooms

Protect against humidity from the ground by storage on wooden frame, in shelf etc.

Cover actuator with foil for protection against dust, dirt etc.

Protect machined surfaces at mounting flange (5.0) coupling (14) and coupling housing by applying an appropriate corrosion protection, e.g. non-acid grease.

13.2.4 TYPE OF DUTY / MOUNTING POSITION

AUMA part-turn actuators in standard-version are suitable for operation at ambient temperatures from -25°C upto +80°C. They are designed for short-time duty S2-15 min. (according to VDE 0530).

AUMA part-turn actuators can be mounted and operated in any position.



13.2.5 MOUNTING OF HANDWHEEL / MANUAL OPERATION

MOUNTING OF HANDWHEEL

Apply grease to handwheel shaft.

Place handwheel (40) on handwheel shaft.

Mount compression spring with washer and cheese head screw (40.043).

Check whether handwheel can be easily pulled out on the handwheel shaft and is pushed back by spring action after releasing.

Place cap (40.043) into handwheel hub.

MANUAL OPERATION

Part turn actuator has a handwheel lock and for releasing the lock pull the handwheel out.

Rotation must start only after releasing the handwheel lock.

13.2.6 MOUNTING TO THE VALVE

For butterfly valves, the recommended mounting position is end position CLOSED (Prior to mounting, bring the part-turn actuator to the mechanical end stop CLOSED by turning the handwheel clockwise.).

For ball valves, the recommended mounting position is end position OPEN (Prior to mounting, bring the part-turn actuator to the mechanical end stop OPEN by turning the handwheel counterclockwise.).

Thoroughly degrease mounting faces of part-turn actuator and valve.

Apply a small quantity of grease to the valve shaft.

Place coupling sleeve onto valve shaft and secure (refer to figure, detail A or B), ensure that dimensions X, Y, and Z are observed (refer to table 1).

Apply non-acidic grease at splines of coupling.

Fit actuator so that fixing holes in actuator and valve mounting flange are in alignment.

If necessary, move actuator up or down one tooth on the coupling. If required, turn handwheel/ crank a little in direction OPEN or CLOSE until holes align to the threads.

Ensure that the spigot (if provided) mates uniformly in the recess and that the mounting faces are in complete contact.

Fasten the actuator with bolts of minimum quality 8.8 using lock washers. Fasten bolts evenly crosswise to the appropriate torque according to table 1.



13.2.7 ELECTRIC CONNECTION

CONNECTION WITH AUMA PLUG/ SOCKET CONNECTOR

Work on the electrical system or equipment must only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules.

Check whether type of current, supply voltage, and frequency correspond to control and motor data (refer to name plates at part-turn actuator and controls).

Loosen bolts (50.01) (see figure) and remove plug cover.

Loosen screws (51.01) and remove socket carrier (51.0) from plug cover (50.0).

Insert cable glands suitable for connecting cables (The enclosure protection stated on the name plate is only ensured if suit-able cable glands are used.).

Seal cable entries which are not used with suitable plugs.

Connect cables according to order-related terminal plan.

Refer GEA wiring diagram for the terminal plan pertaining to the part-turn actuator.

Table 1: Dimensions for couplings/ fastening torques for bolts

T y p e X m a x . Y m a x . Z

m a x . 8 . 8 T A [ N m ]

SG(R) 05.1-F05 5 3 60 4 x M 6 11

SG(R) 05.1-F07 5 3 60 4 x M 8 25

SG(R) 07.1-F07 7 3 60 4 x M 8 25

SG(R) 07.1-F10 7 3 60 4 x M 10 51

SG(R) 10.1-F10 10 3 77 4 x M 10 51

SG(R) 10.1-F12 10 3 77 4 x M 12 87

SG(R) 12.1-F12 10 6 100 4 x M 12 87

SG(R) 12.1-F14 10 6 100 4 x M 12 87



Table 2: Technical data AUMA plug/ socket connector

Technical data Power terminals1) Protective earth Control terminals

No. of contacts max. 6 (3 are used) 1 (leading contact) 50 pins/ sockets

Marking U1, V1, W1, U2, V2, W2 1 to 50

Connecting voltage max. 750 V – 250 V

Current max. 25 A – 16 A

Type of customer connection Screws Screw for ring lug Screws

Cross section max. 6 mm2 6 mm2 2.5 mm2

Material: Pin/ socket carrier Contacts

Polyamide Polyamide Polyamide

Brass (Ms) Brass (Ms) Brass, tin plated or gold plated (option)

1) Suitable for copper wires. For aluminium wires, please contact AUMA

AUMA MATIC ON THE WALL BRACKET

The AUMA MATIC can also be mounted separately from the actuator on a wall bracket.

For the connection of actuator and AUMA MATIC on wall bracket, use suitable flexible and screened connecting cables (Connecting cables are available on request.).

Permissible cable distance between actuator and AUMA MATIC amounts to a max. of 100 m.

Versions with potentiometer in the actuator are not suitable. Instead of the potentiometer, an RWG has to be used in the actuator.

Connect the wires to the actuator in correct phase sequence.

Check the direction of rotation before switching on. FITTING THE COVER After connection,

Insert the socket carrier (51.0) into the plug cover (50.0) and fasten it with screws (51.01).

Clean sealing faces at the plug cover and the housing.

Check whether O-ring is in good condition.

Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.

Replace plug cover (50.0) and fasten bolts (50.01) evenly crosswise.

Fasten cable glands with the specified torque to ensure the required enclosure protection.



13.2.8 SETTING OF END STOPS FOR PART-TURN ACTUATORS ON BUTTERFLY VALVES

The settings can only be performed if the valve has not yet been mounted in a pipeline. SETTING ENDSTOP CLOSED

If hex. bolts (03) are fastened, loosen by approx. 3 turns.

Turn handwheel counterclockwise (closing direction), until valve is closed (end position CLOSED).

Check whether end stop (10) has rotated, otherwise turn end stop (10) clockwise up to the stop.

In case end position CLOSED has been passed, reverse several turns at the handwheel and approach end position CLOSED again.

Turn end stop (10) by 1/8 turn counterclockwise (Protective cap (16) must not be loosened in the process).

Fasten hex. bolts (03) crosswise with torque 25 Nm

SETTING ENDSTOP OPEN The swing angle has been set in the factory. Therefore, the end stop OPEN need not be set. SETTING LIMIT SWITCH CLOSED After setting the end stop CLOSED, the limit switching for end position CLOSED can be set immediately. For this, the switch compartment has to be opened and the indicator disc has to be removed. 13.2.9 CHANGING THE SWING ANGLE

The swing angle only has to be changed if the swing range for setting the end stops is not sufficient.

Unless ordered otherwise, the swing angle is set to 90°.

In the standard version, the swing angle can be adjusted within the range of 80° to 110°. Optional swing angle ranges can also be availed as in Technical Data.



INCREASING THE SWING ANGLE

Unscrew protective cap (16).

While holding end stop nut (2.4) in position with open end wrench

(19 mm), remove grub screw (2.02).

Turn end stop nut (2.4) counterclockwise. Do not exceed dimension A max. (table 3).

Move valve manually to the desired end position OPEN.

Turn end stop nut (2.4) clockwise until it is tight up to the stop nut (7).

Degrease face of grub screw (2.02).

Hold end stop nut in position (2.4) with open end wrench (19 mm) and fasten grub screw (2.02) with torque 85 Nm.

Check O-ring (016) and replace if damaged.

Replace protective cap (16).

REDUCING THE SWING ANGLE

Unscrew protective cap (16).

While holding end stop nut (2.4) in position with open end wrench (19 mm), remove grub screw (2.02).

Move valve into the desired end position OPEN.

Turn end stop nut (2.4) clockwise until it is tight up to the stop nut (7) and do not fall below dimension A min. (Table 3)

Degrease face of grub screw (2.02).

Hold end stop nut in position (2.4) with open end wrench (19mm) and fasten grub screw (2.02) with torque 85 Nm.

Check O-ring (016) and replace if damaged.

Replace protective cap (16).

Table 3

Type A min. [mm] A max. [mm]

SG 05.1/ SGR 05.1 10 22

SG 07.1/ SGR 07.1 10 22

SG 10.1/ SGR 10.1 8 17

SG 12.1/ SGR 12.1 12 23



13.2.10 OPENING THE SWITCH COMPARTMENT

Remove 4 bolts and take off the cover at the switch compartment

Pulling off the indicator disc. Open end wrench (approx. 14 mm) may be used as lever. 13.2.11 SETTING THE LIMIT SWITCHING

SETTING END POSITION CLOSED (BLACK)

Turn handwheel clockwise until valve is closed.

To prevent that the end stop is reached (due to overrun) before the limit switch has tripped, turn handwheel 4 turns (overrun) in counterclockwise direction. During test run check overrun and, if necessary, correct setting of the limit switching.

Press down and turn setting spindle A with screw driver (5 mm) in direction of arrow, thereby observe pointer B.

While a ratchet is felt and heard, the pointer B moves 90° every time. When pointer B is 90° from mark C, continue turning slowly.

When pointer B has reached the mark C, stop turning and release setting spindle. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped), continue turning the setting spindle in the same direction and repeat setting process.



SETTING END POSITION OPEN (WHITE SECTION)

Turn handwheel counterclockwise until valve is open.

To prevent that the end stop is reached (due to overrun) before the limit switch has tripped, turn handwheel 4 turns (overrun) in clockwise direction. During test run check overrun and, if necessary, correct setting of the limit switching.

Press down and turn setting spindle D with screw driver (5 mm) in direction of arrow, thereby observe pointer E. While a ratchet is felt and heard, the pointer E moves 90° every time. When pointer E is 90° from mark F, continue turning slowly. When pointer E has reached the mark F, stop turning and release setting spindle. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped), continue turning the setting spindle in the same direction and repeat setting process.

CHECKING THE LIMIT SWITCHES The red test buttons T and P are used for manual operation of the limit switches.

Turning T in direction of the arrow LSC (WSR) triggers limit switch CLOSED.

Turning P in direction of the arrow LSO (WÖL) triggers limit switch OPEN.

After checking the switches, the fault (red indication light) has to be reset using the OPEN or CLOSE push buttons of the local controls for operation in the opposite direction.

13.2.12 SETTING THE TORQUE SWITCHING

The set torque must suit the valve!

This setting must only be changed with the consent of the valve manufacturer!

Loosen both lock screws O at the torque dial

Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm). Example: the above figure shows the following setting:

11.5 da Nm = 115 Nm for direction CLOSE

12.5 da Nm = 125 Nm for direction OPEN

Tighten lock screws O again

The torque switches can also be operated in manual operation.

The torque switching acts as overload protection over full travel, also when stopping in the end positions by limit switching.



CHECKING THE TORQUE SWITCHES The red test buttons T and P are used for manual operation of the torque switches:

Turning T in direction of the arrow TSC (DSR) triggers torque switch CLOSED.

Turning P in direction of the arrow TSO (DOEL) triggers torque switch OPEN.

If a DUO limit switching (optional) is installed in the actuator, the intermediate position switches will be operated at the same time.

After checking the switches, the fault (red indication light) has to be reset using the OPEN or CLOSE push buttons of the local controls for operation in the opposite direction.

13.2.13 TEST RUN CHECKING THE DIRECTION AND ROTATION

Place indicator disc on shaft.

The direction of rotation of the indicator disc (see figure) indicates the direction of rotation of the output drive.

Move actuator manually to intermediate position or to sufficient distance from end position.

Set selector switch to local control (I)

Switch on the power supply.

Press push button CLOSE and observe the direction of rotation: If the indicator disc turns clockwise, the direction of rotation is correct.

If the direction of rotation is wrong, switch off immediately. Afterwards correct phase sequence in the connecting cable from the wall bracket to the actuator and repeat test run

Push button CLOSED Push button STOP



CHECKING THE LIMIT SWITCHING

Set selector switch to position OFF (0).

Move actuator manually into both end positions of the valve.

Check whether limit switching is set correctly. Hereby observe that the appropriate switch is tripped in each end position and released again after the direction of rotation is changed. If this is not the case, the limit switching must first be set, as described earlier. When limit switching is set correctly:

Set selector switch to local control (I) (figure 15).

Perform test run at the local controls via push buttons OPEN - STOP - CLOSE.

Close switch compartment

13.2.14 SETTING THE ELECTRONIC POSITION TRANSMITTER (RWG) — For remote indication or external control — After mounting the part-turn actuator to the valve, check setting by measuring the output current and re-adjust, if necessary.

The position transmitter board is located under the cover plate SETTING 3- / 4- WIRE SYSTEM 4 – 20 mA

Connect voltage to electronic position transmitter.

Move valve to end position CLOSED.

Pull off indicator disc.

Table 4: Technical data RWG 4020

Terminal plans

KMS TP_ _ 4 / _ _ _ 3- or 4- wire system

KMS TP _ 4 _ / _ _ _ KMS TP _ 5 _ / _ _ _ 2-wire system

Output current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA

Power supply Uv 24 V DC, ±15 % smoothed

14 V DC + (I x RB), max. 30 V

Max. input current

I 24 mA at 20 mA output current

20 mA

Max. load RB 600

(Uv - 14 V) / 20 mA

Positioner Board



Connect ammeter for 0 – 20 mA to measuring points.

The circuit (external load) must be connected (observe max. load RB), or the appropriate poles at the terminals (refer to wiring diagram) must be linked, otherwise no value can be measured.

Turn potentiometer (E2) counterclockwise until stop is felt.

Turn potentiometer (E2) slightly back.

Turn potentiometer “0” clockwise until output current starts to increase.

Turn back potentiometer “0” until a residual current of approx. 0.1 mA is reached.

Move valve to end position OPEN.

Set potentiometer “max.” to end value 16 mA.


Set potentiometer “0” from 0.1 mA to initial value 4 mA.

This results in a simultaneous shift of the end value by 4 mA, so that the range is now 4 - 20 mA.

Approach both end positions anew and check setting. If necessary, correct the setting. If the maximum value cannot be reached, the selection of the reduction gearing must be checked. 13.2.15 SETTING OF MECHANICAL POSITION INDICATOR

Place indicator disc on shaft.


Turn lower indicator disc until symbol CLOSED is in alignment with the mark on the cover.

Move actuator to end position OPEN.

Hold lower indicator disc in position and turn upper disc with symbol OPEN until it is in alignment with the mark on the cover.

The indicator disc turns approx. 180° for a swing angle of 90°.



13.2.16 CLOSING THE SWITCH COMPARTMENT

Clean sealing faces of housing and cover


Apply a thin film of non-acidic grease to the sealing faces.

Replace cover on switch compartment and fasten bolts evenly crosswise. 13.2.17 SETTING THE OPERATING TIME

Remove motor cover.

Set required operating time with potentiometer.

Clean sealing faces of housing and motor cover.


Apply a thin film of non-acidic grease to the sealing faces.

Fit and fasten motor cover (for enclosure protection IP 68, the motor cover is additionally sealed with thread sealing material.)

Table 5: Operating times for 90°

SG 05.1 5.6 to 45 seconds

SG 07.1 11 to 90 seconds





13.2.18 ACTUATOR CONTROLS AUMA MATIC Functions of the diagnosis LEDs on the interface board (standard vision) V14 is illuminated: Phase failure and/ or motor protection tripped.

In combination with motor protection (PTC thermistor): Reset by selector switch position I I I at local controls

V15 is illuminated: Torque fault: Torque switch operated in mid-travel The LEDs STOP, CLOSE, OPEN indicate the available control commands (only in selector switch position REMOTE).

Positions of the boards within controls

Cover Plate on interface board



Programming the logic board

The type of seating – limit or torque seating – (switch S1-2 and switch S3-2) must be determined by the valve manufacturer.

Set desired programming according to table 6 at the switch S2-2.

T a b l e 6

D I P s w i t c h S 2 - 2 P r o g r a m m i n g

(ON = pressed)

Direction CLOSE Direction OPEN

Self-retaining REMOTE

Push-to-run operation REMOTE

Self-retaining LOCAL

Push-to-run operation LOCAL

Blinker transmitter (option)

activated deactivated

Torque fault: Torque switch tripping (in mid-travel) contained in collective fault signal

Included not included



EMERGENCY-OPEN and EMERGENCY-CLOSE signal (option) (5th digit in wiring diagram MSP … C, D, or P) When an EMERGENCY run command is given the actuator operates the valve to the predetermined end position (effective in all three selector switch positions: LOCAL, OFF, REMOTE).

The input at terminal XK 1 (refer to wiring diagram) must be connected to an NC contact (closed circuit principle) at + 24 V DC.

If EMERGENCY- OPEN or EMERGENCY CLOSE signal is generally not desired:

Take off cover plate and disconnect links B1 (for EMERGENCY - CLOSE) and B2 (for EMERGENCY - OPEN).

13.2.19 ELECTRONIC POSITIONER (OPTION) Technical data

Table 7: Technical data for positioner

Command signal (input signal E1, set value) 0/4 – 20 mA (Option: 0 – 5 V)

Feedback (input signal E2, actual value) 0/4 – 20 mA (Option: 0 – 5 V)

Sensitivity (dead band) ÄE (P9) 0.5 % – 2.5 %

Fine tuning “Sens” (P7) (useful for output speeds <16 rpm only)

min. 0.25 %

Pause time “t-off ”(P10) 0.5 – 10 s

Input resistance 250 Ohm

Modulating duty with stepping mode (not required for modulating setting): Running time “t-on ” (P8)

effective until error is ≤ 25 %; then set value is

automatically reduced by 3.

0.5 – 15 s

Cover plate for EMERGENCY- OPEN or EMERGENCY- CLOSE option

Links: B1 (EMERGENCY - CLOSE) B2 (EMERGENCY - OPEN)

LED FOR EMERGENCY run command



Setting The positioner in the actuator controls AUMA MATIC is programmed according to the purchase order details and is set together with the actuator prior to delivery. Due to peculiarities of the regulating system not known beforehand, a readjustment may become necessary. Before adjusting the positioner, the programming of the positioner should be checked. Check programming of the logic board

The self-retaining REMOTE function (see table 6) must be switched off in conjunction with the positioner. Take off cover plate and carry out required programming at positioner board according to table 8 and 9. Prior to setting, it must be ensured that the circuit for the position feedback E2 (see wiring diagram) is closed (measuring device or link). In case of missing signal E2, the LED (V10) “E1/E2 < 4 mA” is illuminated and the positioner shows no reaction.

Cover Plate Positioner

Positioner Board A7

Label with signal indication (in our example: E1 = 4 – 20 mA, E2 = 4 – 20 mA)

E1

E2



Setting type of signal

The signal type (current/ voltage signal) of nominal value E1 and actual value E2 is set in the factory and marked with a label on the cover plate of the positioner. If the setting is subject to a subsequent change, the marking also has to be changed. Furthermore the wiring diagram indicated on the name plate of the actuator controls also changes.

Table 8: Possible settings

Command signal Setpoint E1

Feedback Actual value E1)

P r o g r a m m i n g via DIP switch S1-7

4 – 20 mA 0 – 20 mA

4 – 20 mA 0 – 20 mA

4 – 20 mA 0 – 20 mA

0 – 5 V

0 – 5 V 4 – 20 mA 0 – 20 mA

0 – 5 V 0 – 5 V

0 – 10 V 4 – 20 mA 0 – 20 mA

0 – 10 V 0 – 5 V

In case of a loss of signal of nominal value E1 or actual value E2, the reaction of the actuator can be programmed via the switch S2-7. The complete range of choices, however, is only available with signals 4 – 20 mA. The following reactions are possible: Fail as is : Actuator stops immediately and remains in this position. Fail close : Actuator moves the valve to the end position CLOSED. Fail open : Actuator moves the valve to the end position OPEN.



1) During loss of signal, signals from 0 – 20 mA and 0 – 5 V may be misinterpreted since E1 or E2 (without any

fault) can also be 4 mA (end position CLOSED = 0 mA or 0 V) when working properly. 2) Signals for internal feedback:

0/4 – 20 mA from electronic position transmitter or 0 – 5 V from precision potentiometer 5 Ω

Positioner adjustment end position CLOSED (standard version) Before beginning the setting of the positioner, it has to be ensured that the limit and torque switching of the actuator as well as the feedback have been set.

Set selector switch (local controls) to position LOCAL.

Move multi-turn actuator by pressing push button to end position CLOSED.

Supply nominal value E1 of 0 or 4 mA (see wiring diagram).

Turn potentiometer “t-off” (P10) counterclockwise to the stop

Positioner Board A7

Missing signals E1/ E2 or wrong polarity are indicated by LED (V10) “E1/E2 < 4 mA"



Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value (0 – 5 V).

For a nominal value E1 of 0 mA, the voltmeter shows 0 V.

For a nominal value E1 of 4 mA, the voltmeter shows 1 V.

In case nominal value (0 V or 1 V) is not correct: Correct nominal value signal in control room.

Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value signal.

For an actual value E2 of 0 mA, the voltmeter shows 0 V.

For an actual value E2 of 4 mA, the voltmeter shows 1 V.

If measured value is not correct:

Adjust position feedback and repeat “positioner adjustment”.

T a b l e 1 0

If

Possible LED display:

Th

en

Required setting in end position CLOSED:

the LEDs are not illuminated Turn potentiometer “0” (P3) slightly clockwise until

LED (V27 yellow) is illuminated

LED (V28 green) is illuminated

Turn potentiometer “0” (P3) slightly clockwise until

LED (V28 green) is no longer illuminated and



Turn potentiometer “0” (P3) counterclockwise until

LED (V27 yellow) is no longer illuminated.

Then turn potentiometer “0” (P3) slightly to clockwise until


Positioner adjustment end position OPEN (standard version)

Run multi-turn actuator by pressing push button (local controls) to end position OPEN.

Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value E2:

When position feedback is set correctly, the voltmeter shows 5 V. If measured value is not correct:


Connect max. command signal (nominal value E1) = 20 mA.

Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value E1:

For a nominal value of 20 mA, the voltmeter shows 5 V.

If measured value is not 5 V:

Check the externally supplied command signal E1.



Table 11 If

LED display:

Th

en

Required setting in end position OPEN:

the LEDs are not illuminated Turn potentiometer “max.” (P4) slightly counterclockwise until



Turn potentiometer “max” (P4) clockwise until LED (V28

green) is no longer illuminated

Then turn potentiometer “max” (P4) slightly counterclockwise

until LED (V28 green) is illuminated.


Turn potentiometer “max” (P4) slightly counterclockwise until

LED (V27 yellow) is no longer illuminated and


Setting the sensitivity

Set selector switch at the local controls to position REMOTE.

Set command signal E1 according to label on cover plate (see figure). The sensitivity (∆E / dead band) is set to maximum value (2.5 %) in the factory.

With the potentiometer ∆E (P9) the dead band can be increased by turning clockwise. Left stop = small dead band (= high sensitivity). For a precise setting of the dead band, a set point device with setting options in the 0.1 mA range is required.

A better sensitivity ∆Emin = 0.25 %) can be achieved by turning the potentiometer P7 (sens) clockwise.

When setting ∆E, the following must be observed: If the number of starts is too high, this will lead to unnecessary wear at the valve and actuator. Therefore the maximum possible dead band acceptable for the process must be set. To prevent exceeding the max. permissible number of starts (refer to Technical data sheets for modulating actuators) in extreme cases, a pause time between 0.5 s (left stop) and 10s (right stop) may be set with the potentiometer “t-off” (P10).

Cover Plate for Positioner

Label with signal indication (in our example: E1 = 4 – 20 mA, E2 = 4 – 20 mA)

V28 (green) V27 yellow

V8 red

V10 red

P10



Cover Plate for Positioner A7

Positioner adjustment end position OPEN (inverse operation) In standard version the maximum input signal (E1 = 20 mA) results in operation to end position OPEN.

By switching the code switch S3-7 to position “1” an inversion of this signal definition (inverse operation) can be achieved.

In case an RWG (option) is installed, the connections 7 (red) and 5 (black) on the positioner board of the actuator have to be exchanged.

In case a potentiometer is installed, (option) the connections 21 (red) and 22 (black) at the potentiometer must be interchanged.

Before beginning the setting of the positioner, it has to be ensured that the limit and torque switching of the actuator as well as the feedback have been set.

Set selector switch (local controls) to position LOCAL.

Run actuator with push button to End position OPEN

Supply nominal value E1 of 0 or 4 mA (see wiring diagram).

Turn potentiometer “t-off” (P10) counterclockwise to the stop

Missing signals E1/ E2 or wrong polarity are indicated by LED (V10) “E1/E2 4 < mA"

Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value (0 – 5 V).

For a nominal value E1 of 0 mA, the voltmeter shows 0 V. For a nominal value E1 of 4 mA, the voltmeter shows 1 V. In case nominal value (0 V or 1 V) is not correct, Correct nominal value signal in control room.

Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value signal.

E1 E2



For an actual value E2 of 0 mA, the voltmeter shows 0 V. For an actual value E2 of 4 mA, the voltmeter shows 1 V. Adjust position feedback and repeat “positioner adjustment”.

Positioner Board A7

Table 12

If

Possible LED display:

Th

en

Required setting in end position OPEN:

the LEDs are not illuminated Turn potentiometer “0” (P3) slightly clockwise until



Turn potentiometer “0” (P3) slightly clockwise until

LED (V27 yellow) is no longer illuminated and



Turn potentiometer “0” (P3) counterclockwise until

LED (V28 green) is no longer illuminated.

Then turn potentiometer “0” (P3) slightly clockwise until


Positioner adjustment end position CLOSED (inverse operation)

Run actuator with push button (local controls) to end position CLOSED.

Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value E2:

When position feedback is set correctly the voltmeter shows 5 V. If measured value is not correct:


Connect max. command signal (nominal value E1) = 20 mA.



Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value E1:

For a nominal value of 20 mA, the voltmeter shows 5 V.

If measured value is not 5 V:

Check the externally supplied command signal E1.

Table 13

LED display: Required setting in end position CLOSED:

the LEDs are not illuminated Turn potentiometer “max” (P4) slightly counterclockwise until



Turn potentiometer “max” (P4) clockwise until LED (V27

yellow) is no longer illuminated.

Then turn potentiometer “max” (P4) slightly counterclockwise until

LED (V27 yellow) is illuminated.


Turn potentiometer “max” (P4) slightly counterclockwise until the

LED (V28 green) is no longer illuminated and

the LED (V27 yellow) is illuminated.

13.2.20 MAINTENANCE

After maintenance, check part-turn actuator for damage to paint finish. If damage to paint-finish has occurred after mounting, it has to be touched up to avoid corrosion. Original paint in small quantities can be supplied by AUMA.

AUMA part-turn actuators require very little maintenance. Precondition for reliable service is correct commissioning.

Seals made of elastomers are subject to ageing and must therefore regularly be checked and, if necessary, be exchanged.

It is also very important that the O-rings at the covers are placed correctly and cable glands fastened firmly to prevent ingress of dirt or water.

If rarely operated, perform a test run about every 6 months. This ensures that the actuator is always ready to operate.

Approximately six months after commissioning and then every year check bolts between part-turn actuator and valve/gearbox for tightness. If required, tighten applying the torques given in table 1.

13.2.21 LUBRICATION AUMA part-turn actuators are filled with grease for lifetime. A change of grease or re-lubrication is not necessary.



13.2.22 SPARE PARTS



No. Type Description No. Type Designation

1 E Housing 36.5 B Mechanical position indicator

2.0 B Worm shaft assly.

36.6* B

Blinker transmitter including pins at wires (without impulse disc and insulation plate) 2.4 E

End stop nut (included in sub-assembly 2.0)

3.0 B Manual drive worm assly. 36.10 E Cover plate

4.0 B Worm wheel 38.0 B Pin carrier (without pins)

5.0 B Mounting flange assly. 38.2.2 B Pin for motor

10.0 B Limit stop housing assly. 38.2.3 B Pin for controls

14 E Coupling 38.2.4 B Wire for protective earth

16 E Cap 39.0 B Plug cover assly.

17.0 B Torque finger assly. 39.2 B

Socket carrier (complete with sockets) 21.0 B Limit drive finger assly.

29.0 B Manual drive bearing assly. 39.2.2 B

Socket for motor (included in sub-assembly 39.2) 32.0 B Planetary gearing assly.

34.0 B Motor assly. 39.2.3 B

Socket for control (included in sub-assembly 39.2) 34.22 B Motor plug pin carrier (without

pins) 39.2.4 B

Socket for protective earth (included in sub-assembly 39.2)

34.23 B Pin for motor

40 B Handwheel assly. 34.24 B Pin for thermoswitch

34.7 B Motor brake 40.043 E Cap assly.

34.8 B Motor electronic board 40.43 B Ball handle assly.

41 B Motor plug, socket assly. 34.9 B Cover plate

35.0 B Cover assly. 152.1* B Potentiometer (without slip clutch)

36.0 B Control unit assly. (without switches)

152.2* B Slip clutch for potentiometer

36.1 B Torque switching head 153.0* B Electronic position transmitter (RWG)

36.2 B Heater 153.1 * B Potentiometer for RWG (without slip clutch)

36.3.1 B Stud bolt for switches 153.2* B Slip clutch for RWG

36.3.2 B Switch for limit/ torque switching (including pins at wires)

153.3* B Electronic board RWG

S 1 S Seal kit (small)

36.3.4 E Spacer S 2 S Seal kit (large)

* not included in basic equipment Note: Please state type and commission no. of the actuator (see name plate) when ordering spare parts. Delivered spare parts may slightly vary from the representation in these instructions.



13.2.23 SPARE PARTS LIST CONTROLS



N o . Description N o . Designation

001.0 Housing 008.1 Interface board

002.0 Local controls 009.0 Logic board

003.0 Local controls board 013.0 Adapter board

003.1 Primary fuse 500.0-1 Cover

003.2 Cover for fuse 501.0 Socket carrier (complete with sockets)

004.0 Switchgear 502.0 Pin carrier (without pins)

004.2 Carrier for contactors 503.0 Socket for control

004.3 Socket carrier (complete with sockets) 504.0 Socket for motor

006.0 Power supply unit including mounting plate 505.0 Pin for controls

006.1 Mounting plate for power supply unit 506.0 Pin for motor

006.2 Power supply unit 507.0 Plug cover

006.2-1 Secondary fuse F3 508.1 Reversing contactors

006.2-2 Secondary fuse F3 509.1 Padlock

008.0 Interface board S1 Seal kit

Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Delivered spare parts may slightly vary from the representation in these instructions.



13.3 DP TRANSMITTER

This write up contains the installation operation and maintenance details of DP Transmitter.



13.3.1 INSTALLATION The Rosemount Differential Pressure Transmitters may be used for accurate measurement of differential pressure of flow. Measurement accuracy depends upon proper installation of the transmitter and impulse piping. Mount the transmitter close to the process and use a minimum of piping to achieve best accuracy. Keep in mind the need for easy access, personnel safety, practical field calibration, and a suitable transmitter environment. Install the transmitter to minimize vibration, shock, and temperature fluctuation. Differential Pressure transmitters are often installed in harsh environments due to process and economic considerations. The transmitter should, however, be located to minimize the effects of temperature gradients and fluctuations, and to avoid vibration and shock.

13.3.2 LOCATION The best location for the transmitter in relation to the process pipe depends on the process itself. Use the following guidelines to determine transmitter location and placement of impulse piping:

Keep impulse piping as short as possible.

Slope the impulse piping at least 1inch per foot (8 cm per m) upward from the transmitter toward the process connection.

Avoid high points in liquid lines.

Make sure both impulse legs are the same temperature.

Use impulse piping large enough to avoid friction effects and blockage.

Vent all gas from liquid piping legs.

When using a sealing fluid, fill both piping legs to the same level.

When purging, make the purge connection close to the process taps and purge through equal lengths of the same size pipe. Avoid purging through the transmitter.

BLOCK DIAGRAM OF OPERATION



Keep corrosive or hot (above 250°F [121°C]) process material out of direct contact with the sensor module and flanges.

Prevent sediment deposits in the impulse piping.

Keep the liquid head balanced on both legs of the impulse piping.

Avoid conditions that might allow process fluid to freeze within the process flange. 13.3.3 SOURCES OF ERROR The piping between the process and the transmitter must accurately transfer the pressure to obtain accurate measurements. There are five possible sources of error: pressure transfer, leaks, friction loss (particularly if purging is used), trapped gas in a liquid line, liquid in a gas line, and density variations between the legs. 13.3.4 MOUNTING The DP Transmitter is mounted with the use of a mounting bracket to a two inch pipe. Model 3051 process connections on the transmitter flange are 1/4–18 NPT. Flange adapter unions with 1/2–14 NPT connections must be ordered using the DF option. The threads are Class 2; use your plant-approved lubricant or sealant when making the process connections. The process connections on the transmitter flange are on 2 1/8-inch (54mm) centers to allow direct mounting to a three-valve or five-valve manifold. Rotate one or both of the flange adapters to attain connection centers of 2 inches (51mm), 2 1/8 inches (54mm), or 2 ¼ inches (57mm). Install and tighten all four flange bolts before applying pressure, or process leakage will result. When properly installed, the flange bolts will protrude through the top of the module housing. Do not attempt to loosen or remove the flange bolts while the transmitter is in service. The transmitter is calibrated in a horizontal or vertical position at the factory. Mounting the transmitter in a position other than factory calibration position will cause the zero point to shift by an amount equivalent to the liquid head. The transmitter should be rezeroed to cancel the liquid head effect caused by the process connection height differences. Only use bolts supplied with the Model 3051 or sold by Rosemount Inc. as spare parts for the Model 3051 transmitter. To ensure a tight flange, adapter, or manifold seal

Finger-tighten the bolts.

Torque the bolts to the initial torque value using a crossing pattern as per the table.

Torque the bolts to the final torque value using the same crossing pattern as per the table.

Bolt Material Initial Torque Value Final Torque Value

CS-ASTM-A445 Standard 300 in.-lb (34 N-m) 650 in.-lb (73 N-m)

316 SST—Option L4 150 in.-lb (17 N-m) 300 in.-lb (34 N-m)

ASTM-A-193-B7M—Option L5 300 in.-lb (34 N-m) 650 in.-lb (73 N-m)

Monel®—Option L6 300 in.-lb (34 N-m) 650 in.-lb (73 N-m)



13.3.5 WIRING The transmitter terminal block is in the compartment of the electronics housing labeled “FIELD TERMINALS.” The other compartment contains the transmitter electronics module. Connections for the HART-based communicator are attached beneath the terminal screws on the terminal block. You can connect the Rosemount Model 282 Loop Validator at the signal terminals to provide power to the transmitter temporarily for calibration or diagnostic purposes. Or you can attach it to the test connections on the terminal block of the transmitter for indication purposes. Use shielded twisted pairs to yield best results. In order to ensure proper communication, use 24 AWG or larger wire, and do not exceed 5000 feet (1500 meters). Installed signal wiring should not be run together and should not be in the same cable tray as AC power wiring. Connect the lead that originates at the positive side of the power supply to the terminal marked “+” and the lead that originates from the negative side of the power supply to the terminal marked “–”. Avoid contact with the leads and terminals. Do not connect the powered signal wiring to the test terminals. Power could damage the test diode in the test connection.

CAUTION If the test diode is accidentally destroyed, the transmitter can still be operated without local indication by jumping the test terminals. Plug and seal unused conduit connections on the transmitter housing to avoid moisture accumulation in the terminal side of the housing. If you do not seal the unused connections, mount the transmitter with the electrical housing positioned downward for drainage. Install wiring with a drip loop. Arrange the drip loop so the bottom is lower than the conduit connections and the transmitter housing. Do not run signal wiring in conduit or open trays with power wiring, or near heavy electrical equipment. You may ground the signal wiring at any one point on the signal loop, or leave it ungrounded. The negative terminal of the power supply is a recommended grounding point. Device must be properly grounded or earthed according to local electric codes.

WIRING DIAGRAM



Do not remove the transmitter covers in explosive environments when the circuit is live. Transmitter covers must be fully engaged to meet Explosion-Proof requirements. Before connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices. Avoid contact with the leads and terminals. High voltage that may be present on leads can cause electrical shock. For 4–20 mA transmitters, you will need a power supply capable of providing 10.5 to 55 V dc at the transmitter, and a meter to measure output current. To enable communication, a resistance of at least 250 ohms must be present between the communicator or AMS loop connection and the power supply. The dc power supply should provide power with less than 2 percent ripple. The total resistance load is the sum of the resistance of the signal leads and the load resistance of the controller, indicator, and related pieces. Note that the resistance of intrinsic safety barriers, if used, must be included. 13.3.6 CALIBRATION Calibration process is done in three steps with a smart transmitter:

Rerange —sets the 4 and 20 mA points at the desired pressures;

Sensor Trim—adjusts the position of the factory characterization curve to optimize the transmitter performance over a specified pressure range or to adjust for mounting effects

Analog Output Trim—adjusts the analog output to match the plant standard or the control loop. The Range Values command sets the 4 and 20 mA points (lower and upper range values). Setting the range values to the limits of expected readings maximizes transmitter performance. In practice, you may reset the transmitter range values as often as necessary to reflect changing process conditions. The transmitters can be reranged in any one of the three modes : 1. Rerange with a communicator only 2. Rerange with a Pressure Input Source and a Communicator 3. Rerange with a Pressure Input Source and the Local Zero and Span Buttons Reranging using only the communicator is the easiest and most popular way to rerange the transmitter. This method changes the values of the analog 4 and 20 mA points independently without a pressure input. Reranging using the communicator and a pressure source or process pressure is a way of reranging the transmitter when specific 4 and 20 mA points are not known. This method changes the values of the analog 4 and 20 mA points. Reranging using the local zero and span adjustments and a pressure source is a way of reranging the transmitter when specific 4 and 20 mA points are not known and a communicator is not available. You can trim the sensor using either the full trim or the zero trim function. The trim functions vary in complexity, and their use is application-dependent. Both trim functions alter the transmitter’s interpretation of the input signal. The Analog Output Trim commands allow you to adjust the transmitter’s current output at the 4 and 20 mA points to match the plant standards. This command adjusts the digital to analog signal conversion.



13.3.7 SETTING OF JUMPERS Security (Write Protect) There are three security methods with the Model 3051 transmitter:

1. Security Jumper: prevents all writes to transmitter configuration. 2. Local Keys (Local Zero and Span) Software Lock Out: prevents changes to transmitter

range points via local zero and span adjustment keys. With local keys security enabled, changes to configuration are possible via HART.

3. Physical Removal of Local Keys (Local Zero and Span) Magnetic Buttons: removes ability to use local keys to make transmitter range point adjustments. With local keys security enabled, changes to configuration are possible via HART.

NOTE If the security jumper is not installed, the transmitter will continue to operate in the security OFF configuration. You can prevent changes to the transmitter configuration data with the write protection jumper. Security is controlled by the security (write protect) jumper located on the electronics board or display face. Position the jumper on the transmitter circuit board in the “ON” position to prevent accidental or deliberate change of configuration data. If the transmitter write protection jumper is in the “ON” position, the transmitter will not accept any “writes” to its memory. Configuration changes, such as digital trim and reranging, cannot take place when the transmitter security is on. Configuring Transmitter Alarm and Security Jumper Procedure To reposition the jumpers, follow the procedure described below :

If the transmitter is installed, secure the loop and remove power.

Remove the housing cover opposite the field terminal side. Do not remove the transmitter covers in explosive atmospheres when the circuit is live.

Reposition the jumpers as desired. (Refer Figure for jumper positions and the transmitters with optional LCD display)

Reattach the transmitter cover. Transmitter covers must be fully engaged to meet Explosion-Proof requirements.



NOTE Security jumper not installed = Not Write Protected Alarm jumper not installed = High Alarm

NOTE Security jumper not installed = Not Write Protected Alarm jumper not installed = High Alarm

ELECTRONIC BOARD

OPTIONAL LCD DISPLAY



SECTION XIV

CATALOGUES

VF 49...P(IEC)

VF 49_ BN_2D

M M1 M2 N N1 N2 N3 N4 LB AC

VF 49 P63 B5 11 12.8 4 140 115 95 10.5 9.5

3.0

63 184 121

VF 49 P71 B5 14 16.3 5 160 130 110 10.5 9.5 71 219 138

VF 49 P80 B5 19 21.8 6 200 165 130 10 11.5 80 234 156

VF 49 P63 B14 11 12.8 4 90 75 60 7 6 63 184 121

VF 49 P71 B14 14 16.3 5 105 85 70 10.5 6.5 71 219 138

VF 49 P80 B14 19 21.8 6 120 100 80 10 7 80 234 156

U

FA_

F_

IEC

geaed-desn-01

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geaed-desn-01

Line

53

1500min-1-S1

4P

frenoc.c./d.c.brake

G.S.-bremse/freinc.c.

frenoc.a./a.c.brake

W.S.-bremse/freinc.a.

FD

FA

BA

Pn

kW

n

min-1

Mn

Nm

%

cos

In A

(400V)

Is In

Ms

Mn

Ma

Mn

Jm x10-4

kgm2

IMB5

Mod

Mb

Nm

Zo

1/h

NB

SB

Jm x10-4

Kgm2

IMB5

Mod.

Mb

Nm

Zo

1/h

Jm x10-4

kgm2

IMB5

Mod.

Mb

max

Nm

Zo

1/h

Jm x10-4

kgm2

IMB5

0.06BN56A

41350

0.42

47

0.62

0.30

2.6

2.3

2.0

1.5

3.1

0.09BN56B

41350

0.64

52

0.62

0.40

2.6

2.5

2.4

1.5

3.1

0.12BN63A

41310

0.88

51

0.68

0.50

2.6

1.9

1.8

2.0

3.5

FD02

1.7510000130002.6

5.2

FA02

1.7513000

2.6

5.0

BA60

59000

4.0

5.8

0.18BN63B

41320

1.30

53

0.68

0.72

2.6

2.2

2.0

2.3

3.9

FD02

3.5

10000130003.0

5.6

FA02

3.5

13000

3.0

5.4

BA60

59000

4.3

6.2

0.25BN63C

41320

1.81

60

0.69

0.87

2.7

2.1

1.9

3.3

5.1

FD02

3.5

7800100003.9

6.8

FA02

3.5

10000

3.9

6.6

BA60

58500

5.3

7.4

0.25BN71A

41375

1.74

62

0.77

0.76

3.3

1.9

1.7

5.8

5.1

FD03

3.5

7700110006.9

7.8

FA03

3.5

11000

6.9

7.5

BA70

89700

7.8

9.0

0.37BN71B

41370

2.6

65

0.77

1.07

3.7

2.0

1.9

6.9

5.9

FD03

5.0

60009400

8.0

8.6

FA03

5.0

9400

8.0

8.3

BA70

88500

8.9

9.8

0.55BN71C

41380

3.8

69

0.74

1.55

4.1

2.3

2.3

9.1

7.3

FD53

7.5

4300870010.2

10

FA03

7.5

8700

10.2

9.7

BA70

88000

11.1

11.2

0.55BN80A

41390

3.8

72

0.77

1.43

4.1

2.3

2.0

15

8.2

FD04

10

4100800016.6

12.1

FA04

10

8000

16.6

12.0

BA80

18

7400

18

13.5

0.75BN80B

41400

5.1

75

0.78

1.85

4.9

2.7

2.5

20

9.9

FD04

15

41007800

22

13.8

FA04

15

7800

22

13.7

BA80

18

7400

23

15.2

1.1

BN80C

41400

7.5

75

0.79

2.68

5.1

2.8

2.5

25

11.3

FD04

15

26005300

27

15.2

FA04

15

5300

27

15.1

BA80

18

5100

28

16.6

1.1

BN90S

41400

7.5

73

0.77

2.82

4.6

2.6

2.2

21

12.2

FD14

15

48008000

23

16.4

FA14

15

8000

23

16.3

BA90

35

6500

28

19.5

1.5

BN90LA

41410

10.2

77

0.77

3.7

5.3

2.8

2.4

28

13.6

FD05

26

34006000

32

19.6

FA05

26

6000

32

20.3

BA90

35

5400

35

21

1.85BN90LB

41400

12.6

77

0.78

4.4

5.2

2.8

2.6

30

15.1

FD05

26

32005900

34

21.1

FA05

26

5900

34

21.8

BA90

35

5400

37

22

2.2

BN100LA4

1410

14.9

78

0.76

5.4

4.5

2.2

2.0

40

18.3

FD15

40

26004700

44

25

FA15

40

4700

44

25BA100

50

4000

52

29

3BN100LB4

1410

20

80

0.78

6.9

52.3

2.2

54

22

FD15

40

24004400

58

28

FA15

40

4400

58

29BA100

50

3800

66

32

4BN112M

41420

27

83

0.78

8.9

5.6

2.7

2.5

98

30

FD06S

60

—1400

107

40

FA06S

60

2100

107

42BA110

75

2000

114

43

5.5

BN132S

41440

36

84

0.80

11.8

5.5

2.3

2.2

213

44

FD56

75

—1050

223

57

FA06

75

1200

223

58BA140

150

1200

263

76

7.5

BN132MA4

1440

50

85

0.81

15.7

5.7

2.5

2.4

270

53

FD06

100

—950

280

66

FA07

100

1000

280

71BA140

150

1000

320

85

9.2

BN132MB4

1440

61

86

0.81

19.1

5.9

2.7

2.5

319

59

FD07

150

—900

342

75

FA07

150

900

342

77BA140

150

900

369

91

11

BN160MR4

1440

73

87

0.82

22.3

5.9

2.7

2.5

360

70

FD07

150

—850

382

86

FA07

150

850

382

88

15

BN160L

41460

98

89

0.82

29.7

5.9

2.3

2.1

650

99

FD08

200

—750

725

129

FA08

200

750

710

128

18.5

BN180M

41460

121

89

0.81

37.0

6.2

2.6

2.5

790

115

FD08

250

—700

865

145

FA08

250

700

850

144

22

BN180L

41465

143

89

0.82

45

6.5

2.5

2.5

1250

135

FD09

300

—400

1450

175

30

BN200L

41465

196

90

0.83

58

7.1

2.7

2.8

1650

157

FD09

400

—300

1850

197

50Hz

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NOTE :These values refer to the rear shaft end.

geaed-desn-01

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APPD

DT

CHKD

DT

DRN

DT

VHD

INTERVALVE INDIA LTD17/12/2011

GEA BGR ENERGY SYSTEMS INDIA

MOD NOREV DATE SIGN

Customer

Po No 1100006960 Date

Project

IF IN DOUBTASK

Size A B C D E F G H J K L M WT Kgs Qty Tag

300NB (12" 30 6 *300 78 237 270 14 125 8 42 4 30 48 3

29/12/2011

SCALEN.T.S.

TQ No :1141763IV No :

IVGKB BUTTERFLY VALVE WITH BARESHAFT

DRG No : 1/1141763/GKB006-1

Valve Dimensions

KORADI - DF PROJECT

Valve RatingMfg StdTest StdHYD Test

Flange Drilling Std

BodySeat

Notes1) DO NOT USE FLANGE GASKETS DURING VLV INSTALLATION.

ALL DIMS.ARE INDICATIVE EXCEPT FACE TO FACE DIM.BSEAT LEAKAGE-TIGHT SHUT OFF

2)3)4)5)

ALL DIMENSIONS ARE IN MM.FLOW DIRECTION-BI-DIRECTIONAL

ANSI B16.5(#150)PN 10API 609API 598/BS6755 PART I15 KG/CM211 KG/CM2

Pos Qty MocGa Drg Text1 1 A216 GR.WCB+EPOXY+EPDMBONDED BODY SEAT2 1 A351 CF8MDISC3 1 A276/479 SS316 ST HARDSHAFT4 2 STEEL + PTFEGLACIER BEARING5 1 EPDMO RING THRUST PAD6 1 EPDMO RING SHAFT7 2 A276/479 SS 316TAPER PIN8 1 MILD STEEL+EPOXYBOTTOM COVER9 1 B148 AL BRONZE C95800THRUST PAD10 1 POLYACETALTOP BUSH11 1 IS1570 C45/BS970 EN8PARALLEL KEY

Technical data AUMA part-turn actuators SG 05.1 - SG 12.1

Issue 1.98DO 02.02.006GB

We reserve the right to alter data according to improvement made. Previous data sheets become invalid with the issue of this data sheet.

Notes:AUMA motors are provided with thermoswitches to protect the windings(refer to terminal plans KMS). Our warranty will lapse if those thermoswitches arenot connected in the control circuit.Motor data are approximate. Due to usual manufacturing tolerances there may bedeviations from the values given.

Application:Valve attachment:

Electrical operation of valves (e.g. butterfly valves and ball valves).Dimensions according to ISO 5211.

Coupling: unbored splined coupling for connection to the valve shaft, part-turn actuator can berepositioned 4 x 90° on coupling

Self-locking: yesType of duty: short-time duty S 2 - 15 min 1)

Swing angle: standard: 80° to 110° adjustable between min. and max. valueoptions: 25° - 40°, 40° - 55°, 55° - 80°, 110° - 160°, 160° - 230° or 230° - 320°

Limit switching: counter gear mechanism for end positions CLOSED / OPENTorque switching: adjustable torque switching for closing and opening directionOperating time: for 1-phase AC special motors adjustable (see below),

for 3-phase AC motors in steps (see next page)Position indicator: mechanical, continuousHeater in switch compartment: 5 - 20 W, self-regulating

110 - 250 V AC / DC (standard)24 - 48 V (when with AUMA MATIC)

Motors: 3-phase AC motor or 1-phase AC special motorInsulation class: F, tropicalizedMotor protection: thermoswitchesElectrical connection:Terminal plan:

AUMA multi-pin plug, internal wiring of motor and controls on plug/socket connectorKMS TP 100/001 (basic version)

Manual operation: Manual drive for setting and emergency operation, handwheel does not rotate duringelectric operation.

Ambient temperature: standard: – 25 °C to + 70 °C 2)

option: – 40 °C to + 60 °C (low temperature L)Enclosure: IP 67 according to EN 60 529, dust and water tightCorrosion protection: standard: KN, suitable for installation in industrial units, in water- or power plants 3)

option: KS, recommended for installation in aggressive atmospheres, e.g.maritime climate or aggressive chemical substances, as present incertain sections of waste water treatment plants

Finish coating: standard: two-component iron-mica combinationStandard colour: silvergrey (DB 701, similar to RAL 9007)Reference documents: brochure SG 05.1 - SG 12.1

dimension sheet SG 05.1 - SG 12.1

with 1-phase AC motors

Trippingtorque 4)

both directions

ValvemountingflangeISO 5211

Valveshaft

AUMA part-turnactuator type

220 - 240 V; 50/60 Hz(at 110 - 120 V double current

values)

Mot

orpo

wer

5)

Nom

inal

curr

ent

Cur

rent

atm

ax.t

orqu

ean

dsh

orte

stop

erat

ing

time

Sta

rtin

gcu

rren

t

Han

dwhe

eldi

amet

er

Tur

nsfo

r90

°

Wei

ght

6)

min

.Nm

max

.Nm

Sta

ndar

d

Spe

cial

Øm

ax.m

m

Squ

are

max

.mm

Tw

o-fla

tm

ax.m

m

Ope

ratin

gtim

efo

r90

°ad

just

able

kW A appr. A appr. A mmappr.kg

90 150 F 05 F 07 25,4 22 22 SG 05.1 – 5,6 s – 45 s 0,115 1,5 3 3 160 58 19

120 300 F 07 F 10 25,4 22 22 SG 07.1 – 11 s – 90 s 0,115 1,5 3 3 160 58 19

250 600 F 10 F 12 38 30 27 SG 10.1 – 11 s – 90 s 0,230 2 4 4 160 107 25

500 1200 F 12 F 14 50 36 41 SG 12.1 – 22 s – 180 s 0,230 2 4 4 160 110 29

Continuation see next page

1-phase AC (standard voltages and frequencies)

Volt 110 - 120 220 - 240

Hz 50 / 60 50 / 60

1) Based on 20 °C ambient temperature and on anaverage load equal to approx. 50 % of max torque

2) Version AUMA NORM with 3-phase AC motor up to + 80 °C3) If permanently or occasionally exposed to aggressive

substances, a higher corrosion protection KSor KX must be chosen.

4) adjustable between min. and max. values5) at shortest operating time6) with unbored coupling

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SG 05.1 - SG 12.1

Issue 1.98DO 02.02.006GB

1) adjustable between min. and max. values2) at 50 Hz3) with unbored coupling

Notes:AUMA motors are provided with thermoswitches to protect the windings(refer to terminal plans KMS). Our warranty will lapse if those thermoswitches arenot connected in the control circuit.Motor data are approximate. Due to usual manufacturing tolerances there may bedeviations from the values given.Permissible fluctuation of nominal voltage: ± 5 %. If voltage drops below there maybe a reduction of nominal output torque.

We reserve the right to alter data according to improvement made. Previous data sheets become invalid with the issue of this data sheet.

Technical data AUMA part-turn actuators

3-phase AC (standard voltages and frequencies)

Volt 220 230 240 380 400 415 440 460 500

Hz 50 50 50 50 50 50 60 60 50

with 3-phase AC motors

Trippingtorque 1)

both directions

ValvemountingflangeISO 5211

Valve shaft AUMA part-turnactuator type

400 V 50 Hz

Mot

orpo

wer

Mot

orsp

eed

2)

Nom

inal

curr

ent

Cur

rent

atm

ax.

torq

ue

Sta

rtin

gcu

rren

t

Pow

erfa

ctor

Han

dwhe

eldi

amet

er

Tur

nsfo

r90

°

Wei

ght

3)

min

.Nm

max

.Nm

Sta

ndar

d

Spe

cial

∅m

ax.m

m

Squ

are

max

.mm

Tw

o-fla

tm

ax.m

m

Ope

ratin

gtim

efo

r90

°in

seco

nds

2)kW 1/min A appr. A appr. A cos ϕ mm

appr.kg

90 150 F 05 F 07 25,4 22 22

SG 05.1 – 4 0,160 2800 0,60 0,8 1,7 0,67

160 58 18

SG 05.1 – 5,6 0,160 2800 0,60 0,7 1,7 0,67

SG 05.1 – 8 0,090 2800 0,50 0,6 1,0 0,58

SG 05.1 – 11 0,080 1400 0,55 0,6 0,9 0,60

SG 05.1 – 16 0,045 1400 0,35 0,4 0,5 0,60

SG 05.1 – 22 0,045 1400 0,35 0,4 0,5 0,60

120

210

F 07 F 10 25,4 22 22

SG 07.1 – 5,6 0,160 2800 0,60 0,8 1,7 0,67

160 58 18300

SG 07.1 – 8 0,160 2800 0,60 0,8 1,7 0,67

SG 07.1 – 11 0,160 2800 0,60 0,7 1,7 0,67

SG 07.1 – 16 0,090 2800 0,50 0,6 1,0 0,58

SG 07.1 – 22 0,080 1400 0,55 0,6 0,9 0,60

SG 07.1 – 32 0,080 1400 0,55 0,6 0,9 0,60

250

420

F 10 F 12 38 30 27

SG 10.1 – 11 0,160 2800 0,60 0,9 1,7 0,67

160 107 24600

SG 10.1 – 16 0,160 2800 0,60 0,9 1,7 0,67

SG 10.1 – 22 0,160 2800 0,60 0,8 1,7 0,67

SG 10.1 – 32 0,090 2800 0,50 0,7 1,0 0,58

SG 10.1 – 45 0,080 1400 0,55 0,6 0,9 0,60

SG 10.1 – 63 0,080 1400 0,55 0,6 0,9 0,60

500

840

F 12 F 14 50 36 41

SG 12.1 – 22 0,160 2800 0,60 0,9 1,7 0,67

160 110 281200 SG 12.1 – 32 0,160 2800 0,60 0,9 1,7 0,67

840 SG 12.1 – 45 0,080 1400 0,55 0,7 0,9 0,60

1200 SG 12.1 – 63 0,080 1400 0,55 0,7 0,9 0,60

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DimensionsEN ISO

5211A A3 A4 AA

min.B1 B2 B3 1) B4 2) C 4) Ø D Ø D1 Ø D2 Ø D3 E F G H J

SG 05.1/AM F0540 159 199 30 101 137 190 274 337 105 160 40 20 115 115 128 275 50

SG 07.1/AM F07

SG 10.1/AM F10 63 159 199 30 111 172 190 274 347 105 160 40 20 115 150 153 291 56

SG 12.1/AM F12 80 159 199 30 111 172 190 274 347 105 160 40 20 115 150 170 313 70

DimensionsJ1 K L

max.L1 M N P1 3) P2 3) P3 3) R T U Z Ø d1 Ø d2 Ø d3 d4 h h1

SG 05.1/AM150 170 60 63 235 171 M25x1.5 M20x1.5 M32x1.5 232 45 150 32 90

– 50 M6 – 9.5

SG 07.1/AM 55 70 M8 3 13

SG 10.1/AM 150 170 80 63 235 171 M25x1.5 M20x1.5 M32x1.5 242 55 150 32 125 70 102 M10 3 17

SG 12.1/AM 150 192 100 63 235 171 M25x1.5 M20x1.5 M32x1.5 242 55 150 32 150 85 125 M12 3 20

SG 05.1 – SG 12.1SGR 05.1 – SGR 12.1

AM 01.1

Issue 2.09

We reserve the right to alter data according to improvements made. Previous documents become invalid with the issue of this document.

1/2

Y003.513/002/en

Dimensions Part-turn actuators with integral controls AUMA MATIC

AA

ØD

2

Ød2

Ø d3

Ø d1

C

ØD

EAA

M

N

J1

P2

P1

A3

ØD

3

ØD

1

4)

A4

P3

Space required for removal

Valve attachment according to EN ISO 5211Dimensions of couplings see next page

Space required for removal

1) 3ph AC-Motor2) Special 1ph AC-motor and DC motor (Both not suitable for SGR modulating proposes!)3) Standard, other threads on request4) Precise dimension, depending on the AUMA MATIC version

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MS01/MS02 20516013

GI/3097/TCS/OS/ACTBU

G0158

Text Box

BUTTERFLY VALVE ACTUATOR WIRING DIAGRAM

23034063

23034063

ITEM DETAIL

Description

3051CD2A22A1AS2B4M5Q4

Differential Pressure Transmitter

3051CD Transmitter Type: Differential Pressure Transmitter

2 Pressure Range: -250 to 250 inH2O/2.5 inH2O (-623 to 623 mbar/6.2 mbar)

A Transmitter Output: 4-20 mA with Digital Signal Based on HART Protocol

2 Flange Type Flange Material Drain/Vent Flange Adapters: Coplanar, SST, SST

2 Isolating Diaphragm: 316L SST

A O-Ring: Glass-filled PTFE

1 Sensor Fill Fluid: Silicone

A Housing Material Conduit Entry Size: Polyurethane-covered Aluminum, 1/2-14 NPT

S2 Diaphragm Seal Assemblies: Two Remote Seals (Direct Mount or Capillary Connection Type)

B4 Mounting Bracket: Coplanar Flange Brack\et for 2-in. Pipe or Panel Mounting,all SST

M5 Display Type: LCD Display for Aluminum Housing (Housing Codes A, B, C, and D only)

Q4 Calibration Data Certification: Calibration Certificate

1199DDB10ARFW21DAA1HJ

Flanged Remote Seals

1199 Type: Remote Seals

D Seal Location/Capillary Connection Type: Same Seal on Both High and Low Pressure Sides of Transmitter, Welded

D Fill FluidTemp. Limits: D.C. 200

B Inside Diameter inches (mm)Material: 0.028 in. (0.71 mm), 316 SST Armored Sleeving, 0.028

10 Capillary Connection Length: 10 feet (3.0 meters)

A Industry Standard: ANSI (American National Standards Institute)

RFW Process Connection Style: Flanged Remote Seal

2 Process Connection Size: 1-in. (ANSI) 25A (JIS)

1 Flange Pressure Rating: Class 150 (ANSI)

DA Diaphragm MaterialUpper Housing MaterialMounting Flange Material: 316L SST, 316L SST, 316 SST

A Flushing Connection Ring Material (lower housing): 316 SST

1 Flushing Option: One 1/4-in. Flushing Connection

H Non-Sanitary,Flushing Plug; Sanitary,Ra Finish: SST Drain/Vent in Flushing Connections

J Gasket for Lower Housing: Teflon Gasket for Lower Housing

Back Entry, Panel Mounting

Y Yoke Mounting (2” pipe mounting)

P

MOUNTING

Bottom Entry, Surface MountingS

MOVEMENTBrass

CASE

SS304

SS316S6

S4

Die-cast AluminiumAL

SS316S6

DIAPHRAGM / BELLOW

15 - 150 mm

DIAL

Ordering Information

TYPE : IDPS

Please Specify

RANGE

A

B

C

D

E

kg/cm² (g)

Bar (g)

PSI

KPa

mmHg

UNIT

Size Code Rating Code Facing Code

150#

300#

600#

900#

1500#

2500#

RF

FF

RTJ

LT

LG

½”

¾”

1”

1½”

2”

3”

A

B

C

D

E

F

RF

FF

RTJ

LT

LG

15

20

25

40

50

80

F - FLANGED PROCESS CONNECTION **

CONNECTION

SIZE MALE / FEMALE

Male

Female10

6

15

25

20

32

F

M

METRIC THREADS

18 M - M 18 x 1.5

20 M - M 20 x 1.5

24 M - M 24 x 1.5

27 M - M 27 x 2

33 M - M 33 x 2

X X - Any other

40

1/4”

3/8”

1/2”

3/4”

1”

1.1/4”

1.1/2”

TYPE

BP

NT

BT

GS

PF

NS

NPT

BSP

BSPT

PF

Gas

NPSM

www.general-gauges.com46

The recommendations made in this catalogue are to be used as intended guide. No guarantee of material can be undertaken since other factors may affect the performance. We reserve the right to change the specifications mentioned in this catalogue without any notice as

improvements & development is a continuous process at General. Responsibility of typographical errors is specifically disclaimed.

Please Specify

Static Pressure

Chemical Seal Unit-Refer

Catalogue CSU

U

Accessory - Refer

Catalogue ACC

X

D

L

O

N

P

Dual Scale

NACE-MR-01-75

O Cleaning2

2" Pipe Mounting Bracket

Nil

OPTION

B 2SPDT

A 1SPDT

E External zero Adjustment

CE CE Certificate

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Digital Indicator

JIR-301 Series

Standard Features: Multi-Input,Retransmission and 3 Alarms

Model JIR1/8 DIN (96mm x 48mm)

-320 to 2500ºF-199.9 to 750.0ºF

-320 to 1800ºF0 to 3200ºF0 to 3200ºF0 to 3300ºF

-320 to 1500ºF-199.9 to 750.0ºF

-320 to 2300ºF0 to 2500ºF0 to 4200ºF

-200 to 1370ºC-199.9 to 400.0ºC

-200 to 1000ºC0 to 1760ºC0 to 1760ºC0 to 1820ºC

-200 to 800ºC-199.9 to 400.0ºC

-200 to 1300ºC0 to 1390ºC0 to 2315ºC

K

JRSBETNPL-IIC (W/Re5-26)

4 to 20mA DC0 to 20mA DC0 to 1V DC0 to 10V DC1 to 5V DC0 to 5V DC

Input Type Scale

-1999.9 to 9999, -199.9 to 999.9-19.99 to 99.99, -1.999 to 9.999

Thermocouple

DC

• For DC current input a shunt resistor (sold separately) (50Ω) is required.

• StructureUnit available in standard DIN size (1/8 DIN).NEMA 4X protective construction.Black enclosure.

• Programmable AlarmsUnit features standard three alarm outputs.

• True Multi-InputUnit features true multi-input capabilities:10 thermocouple types, 2 RTD types,2 current inputs, and 4 voltage inputs.

• RetransmissionUnit features standard 4-20mA process variableretransmission.Optional outputs available.

• Large LED DisplayAll units feature dual display. PV red 4 digits,Alarm SV green 4 digits.

• ApprovalsUL, cUL and CE Safety Approvals.

• WarrantyAll units manufactured to strict ISO standardsand offer full 3 year manufacturers warranty.

• Low CostMost advanced price/performance package available.

Standard Features Input Range Table

-199.9 to 999.9ºF-300 to 1500ºF

-199.9 to 850.0ºC-200 to 850ºC

Pt100RTD

High Performance Temperature & Recording

Instrumentation

Terminal Wiring

Panel Cutout

TA or TV

Shinko is anISO 9001

facility

DisplayPV.........Red 4-digit Character Size: 16.0 x 7.2 mm (H x W)SV........Green 4-digit Character Size: 10.0 x 4.8 mm (H x W)

Input Thermocouple ----- K, J, R, S, B, E, T, N, PL-II C (W/Re5-26) External resistance: 100Ω or less (However, for B input: 40Ω or less)RTD ------------------ Pt100, 3-wire system (Resistance per wire: 10Ω or less)DC current ---------- 0 to 20mA DC, 4 to 20mA DC Input impedance: 50Ω (Connect shunt resistor 50Ω between input terminals.) Allowable input current: 50mA or less (When shunt resistor 50Ω is used.)DC voltage ---------- 0 to 1V DC Input impedance: 1MΩ or greater Allowable input voltage: 5V or less Allowable signal source resistance: 2kΩ or less 0 to 5V DC, 1 to 5V DC, 0 to 10V DC Input impedance: 100kΩ or greater Allowable input voltage: 15V or less Allowable signal source resistance: 100Ω or less

Thermocouple -------------------- Within ±0.2% ±1digit of each input span ±1 digit or ±2ºC (4ºF) whichever is greater However, R or S input 0 to 200ºC (0 to 400ºF): Within ±6ºC (12ºF) B input 0 to 300ºC (0 to 600ºF): Accuracy is not guaranteed.RTD --------------------------------- Within ±0.1% of each input span, or ±1ºC (2ºF) whichever is greaterDC current and DC voltage ----- Within ±0.2% ±1digit of each input span

Alarm 1 (A1)Alarm 2 (A2)Alarm 3 (A3)

Alarm action and Energized/De-energized can be selected by key operation.The same as the indicating accuracy.ON/OFF actionThermocouple and RTD: 0.1 to 100.0ºC (ºF)DC current and DC voltage: 1 to 1000(The placement of the decimal point follows the selection)Relay contact 3A 250V AC (Resistive load), Electric life: 100,000 times

• Setting accuracy• Action• Hysteresis

• Output

Accuracy(Setting • Indicating)

Input SamplingRate 0.25 seconds

Retransmission

General Specifications

The input value is converted in analog every 0.25 seconds, and it is outputted in DC current.Resolution: 1/12000DC current: 4 to 20mA DC (load resistance, Max 550Ω )Output accuracy: Within ±0.3% of output span

Supply Voltage 100 to 240V AC 50/60Hz, 24V AC/DC 50/60HzAllowable voltage fluctuation: 85 to 264V AC, 20 to 28V AC/DC Power consumption approximately 10VA

Isolation Resistance

500V DC 10MΩ or greater

DielectricStrength

Between Input terminal and Ground terminal, Input terminal and Power terminal ------------ 1.5kV AC for 1 minuteBetween Power terminal and Ground terminal ---------------------------------------------------- 1.5KV AC for 1 minuteBetween Output terminal and Ground terminal, Output terminal and Power terminal -------- 1.5KV AC for 1 minute(Output terminal comprised A1, A2 and A3 output terminals transmission output terminal and communication terminal)

Material Color Material: Flame resistant resin. Color: Black

Environment Ambient temperature: -10 to 50ºC Ambient humidity: 35 to 85%RH (No condensation)

Setting Method Sheet key input

Dimensions 96mm x 48mm x 100mm (W x H x D) Weight: Approximately 300g

Mounting Method Screw type mounting bracket

AttachedFunction

Sensor correction, Setting value lock, Power failure countermeasure, Self-diagnosis, automatic cold junctiontemperature compensation (thermocouple type only), Sensor burnout alarm, Input burnout, Warm-up indication, Dust-proof/Drip-proof IP66, Hold function.

Specified(TA or TV)

Retransmission

The input value is converted in analog every 0.25 seconds, and is outputted in DC current or DC voltage.If this option is applied, the standard transmission output (4 to 20mA) becomes ineffective.Resoulution: 1/12000DC current (TA): 0 to 20mA DC (load resistance, max 500Ω)DC voltage (TV): 0 to 1V DC (load reistance, min. 100kΩ), 0 to 5V DC (load resistance, min. 500kΩ) 1 to 5V DC (load resistance, min. 500kΩ), 0 to 10V DC (load resistance, min. 1MΩ)Output accuracy: Within ±0.3% of output span

Operates various setting value changes, setting value readings and settings from external computer.If this option is added, Hold function is not available.Code form --------------------------------- ASCIIConnectable units ------------------------ A maximum of 31 units per host computerData transfer rate ------------------------ 9600 bps (2400/4800/19200 bps changeable by key operation)Communication system ------------------ Half-duplex start stop synchronousError detection ---------------------------- Parity check, checksum

SerialCommunication

(C5)

TransmitterPower Supply

(P24)

24V DC from terminals 9 and 10, and this becomes the power source for a 2-wire transmitter.If this option is added, Alarm 2 (A2) output is not available.Output voltage: 24V ±3V DC (when load current is 30mA)Ripple voltage: 200mV (when load current is 30mA)Max. load current: 30mA

Options

Input Thermocouple: K, J, R, S, B, E, T, C (W/Re5-26), N, PL-II

Standard Specifications

Input Switching 6-point push button switch (Push button head: Black)

Material, Color Material: Flame resistant resin, Color: Light gray

Mounting Flush, Mounting bracket: One-touch type (Panel thickness: Within 1 to 3 mm), Weight: Approx. 250g

INPUT CODEMulti-range T/C, RTD, DC M

SUPPLY VOLTAGE CODE

24 V/DC 24V100 - 240V AC ---

JIR-301-M ___ ___

Model Number Configuration

OPTIONS* CODE

Retransmission • DC current 0 to 20mA DC TA • DC voltage 0 to 1V DC,0 to 5V DC TV 1 to 5V DC, 0 to 10V DCTransmitter Power Supply 24V DC P24RS-485 C5

• When the option P24 is added, Alarm 2 output is not available.• When the option C5 is added, Hold function is not available.

Terminal Arrangement

Selector Switch (Model FS-106-E)

Panel Cutout



SECTION XV

DRAWINGS

KEY BENEFITS OF GEA BGR TUBE CLEANING SYSTEM & DEBRIS FILTER

Increase in the Heat Transfer Rate

Optimum Turbine Back Pressure

Optimum Power Generation

Avoidance of Corrosion/Erosion of Condenser Tubes

Life Enhancement of Condenser Tubes

No Shutdown for Manual Cleaning

Economy in Fuel Cost

Low Chemical cost for Water Treatment

Typical payback period of 12-18 months on investment

CONTACT :

GEA BGR ENERGY SYSTEM INDIA LIMITED

443, ANNA SALAI, TEYNAMPET, CHENNAI - 600 018. INDIA.

TEL: (+91 44) 2433 5958 FAX : (+91 44) 2434 3374

E-Mail : [email protected] Website : www.bgrcorp.com

Documents

Operation and maintence maunal of boiler feed pump