Betriebsanleitung Engl PDF

Version 1 (05/02)
Replaces
Operating Manual
This operating manual is meant for persons operating,

monitoring, or maintaining the boiler system.
It contains all information required by you for safe operation,
as well as for maintenance and servicing of the boiler system.
Version 1 (05/02)
Replaces
Impressum
All rights reserved
Copyright by LOOS INTERNATIONAL
Loos Deutschland GmbH
Nuernberger Str. 73, D-91710 Gunzenhausen
This operating manual may - even in excerpts - only be reprinted
or otherwise duplicated with the express written approval of the
company LOOS Deutschland GmbH.
Any type of duplication, publication or storage on storage media of
any type and manner not authorized by LOOS Deutschland GmbH
is in violation of current copyright law and will be prosecuted.
Publisher responsible for the content:
LOOS Deutschland GmbH, Nuernberger Str. 73, D-91710 Gunzenhausen
Editorial office/layout: text und bild Redaktion, Thomas-Schwarz-Strae 47, 85221 Dachau
Preface to the Operating Manual

Version 2 (06/02)
Replaces 1 (05/02)
Preface
Congratulations on the purchase of your new boiler system! Please take sufficient time and carefully and completely read
this operating manual before commissioning or operating the plant or individual parts of it. This operating manual contains all
the information needed for safe operation as well as for maintenance and servicing of the boiler system or individual parts of
this system. The hints on safety are based on the safety, health protection and legal regulations applicable at the time of
printing of this operating manual.
Spare Parts
Only original parts made by Loos International may be used and installed during maintenance work or repairs. These original
parts have been especially engineered and manufactured for our boiler systems. They comply with the high quality requirements of Loos International and provide safety and reliability. We expressly point out that spare parts not tested and approved by Loos International may not be used with this boiler system as this could massively impair the safety and function
of the boiler system. Loos International assumes no responsibility of any kind for such installation work and the resultant
consequences. Any warranty claim lapses if arbitrary modifications are made to the boiler system. It may also happen that
possible official approval may be questioned in this case. This also applies if lead seals applied by the works or sealing wax
applied by the works are damaged or removed.
The special order and inquiry form After Sales Services L006 may be found in register L (forms) for ordering or inquiring
about spare parts.
In addition, you can inquire about or order spare parts online at www.loos.de , or you can contact your customer service
engineer.
Customer Service
You will find the address of the person you should contact in the case of problems, faults or other questions on the service
sticker, which is generally fixed in the top right-hand corner of the control cabinet door.
Maintenance Contract
To ensure that your equipment runs safely and properly, regular maintenance is of crucial importance and will also prevent
equipment failure and save costs. Regular maintenance will help to maintain the value of your system and to guarantee the
long-term, optimum availability of your equipment. This is also backed in many countries by national regulations requiring
that the safety elements of your boiler system are inspected by a qualified person.
We therefore recommend that you take out a Maintenance Contract. Under this contract, our customer service engineers will
take over the regular inspection and maintenance of your boiler system. You can request a quotation for your maintenance
contract at www.loos.de or from your customer service engineer.
Page 1 of 1
Order number:
Boiler No.:
Product designation:
21068100
105495; 105496
LOOS Three-Pass Flame Tube Smoke Tube Boiler
UNIMAT, Type UT-HZ [36000;13,0]; LOOS Three-Pass
Flame Tube Smoke Tube Boiler UNIMAT, Type UT-HZ
[36000;13,0]
27.10.2009
Printing date:
General Informations
No.
Title
Edition
A002
Basic safety instructions
6(03/07)
Operation
No.
Title
Edition
B004
Directive water conditions for hot water boilers
4(10/09)
B006
Regular inspections for shell boilers Maximum permitted working pressure

greater than 1.0 bar or maximum permitted temperature greater than 120C
6(03/04)
B007
Check list for hot water boiler
2(06/05)
Boiler and Boiler components
No.
Title
Edition
C005
Lining of the front reversing chamber Lining of the front reversing chamber
1(01/09)
C007
Burner and flue gas side inspection openings for shell boilers for shell boilers 5(11/08)
with lateral flame tube
C014
Shell boiler for producing hot water
Burner
No.
Title
Edition
D001
Gas regulation module (GRM)
2(03/04)
D512
Combustion manager W-FM100
1/2004
D558
Regulators for gas and dual fuel burners with gas supply pressures up to 4 bar 2007
D673
VLT AutomationDrive FC 300
MG.33.AA.03
Weishaupt
industrial burner WKG80/4-A, version NR (NOX reduced)
1/2009
Equipment for water and steam supply
No.
Title
Edition
E016
Return flow temperature safeguard
2(07/09)
E538
Etaline
1.6.2007
E542
Frequency Converter PumpDrive
14.02.2006
Equipment for fuel supply and heat recovery
No.
Title
Edition
F514
High performance fan
N14-0105
7(12/08)
Page 1
Order number:
Boiler No.:
21068100
105495; 105496
[36000;13,0]
27.10.2009
Printing date:
Specification of procedure
No.
Title
Edition
G012
Wet and Dry Conservation
1(09/04)
G301
Loos-Boiler-Control LBC
2(02/08)
G316
Return flow temperature control with speed controlled lifting pump
1(11/07)
G328
Flue gas heat exchanger pump
1(11/07)
G339
Performance regulation infinitely variable load request via permanent signal

or load request via 3-step signal with positioner Double-flue boiler with oneflue operation
1(08/08)
G361
Burner activation twin fire tube boiler ZFR with individual operation of fire tubes 1(10/08)
G381
Return flow shut-off valve, controlled
Switch box components
No.
Title
Edition
H001
Switching Amplifier B3
4(09/09)
H024
Operating and Monitoring System TP10
1(10/07)
H026
Central Processing Unit CPU313C
1(11/07)
H030
Communication Module CP343-1 Lean Industrial Ethernet
2(10/09)
H032
Communication Module CP342-5 Profibus DP
1(07/08)
H037
Analogue Input Module
1(12/07)
H038
Analogue Output Module SM332
1(12/07)
H519
Measuring transducer IgT-MU
02.01.2008
H522
Universal Frequency Transducer
100240_en_05
Sensors
No.
Title
Edition
E+H
Proline Promag 50P, 53P
07/05
E+H
Energy Manager RMS621
09/07
E+H
Omnigrad M TR15
07/09
I001
Level limiter electrode Type E4B
5(03/09)
I003
Pressure transducer for liquid and gaseous media, with electric locking
5(05/05)
I509
Quantometer QA
09/04
I520
INSTALLATION INSTRUCTIONS Model 107 vLT / 107 vLHT with weighted

pendulum
01/2007
1(10/07)
Page 2
Order number:
Boiler No.:
21068100
105495; 105496
[36000;13,0]
27.10.2009
Printing date:
Armatures and servo units
No.
Title
ARI
Supape de trecere i reglare - STEVI 425/426
ARI
Servomotoare multitur SA 07.1 SA 16.1/SAR 07.1 SAR 16.1 AUMA NORM 01/08
K002
Full-stroke safety valves
K004
Pressure gauge with test stop valve
K007
Stop valves
4(01/09)
K008
Non-return valves
K014
Temperature controller/limiter
K021
Flange gaskets
3(05/02)
K022
Inspection openings steam and water side
16(07/08)
K537
Gas filter HF 2000
K554
Electric multi-turn actuators SA07.1 - SA 48.1 / SAR 07.1 - SAR 30.1
07.06.2006
K557
High performance butterfly valves Series HP111 / HP114
07/08
Forms
No.
Title
Edition
L004
Form operating log book for hot water boiler
3(08/05)
L006
After Sales Service Enquiry/Order
3(04/07)
L007
Regular Inspections - External Inspections
3(08/09)
L008
Regular Inspections - Internal Inspections
3(08/09)
L009
Regular Inspections - Water Pressure Test
3(08/09)
L014
Return Note
2(10/09)
Technical data
No.
Title
Edition
M_KDP
Technical data
---
M_LPK
Project-oriented data sheets from LPK
---
TI012
Requirements for operation of high-pressure boiler systems without constant 3(08/08)

supervision
TI014
Dewpoint of flue gases
4(10/07)
TI024
Requirements for Boiler Installation Rooms
6(07/09)
TI034
Parameter for the Profibus DP Interface
3(10/09)
Edition
Page 3
General Information
Operating Instructions

A002
Version 6 (03/07)
Contents
1
Scope of the Operating Instructions ........................................................................................................................ 2
Use in Accordance with Regulations....................................................................................................................... 2
Safety .......................................................................................................................................................................... 2
3.1
General ........................................................................................................................................................................ 2
3.2
Definition of terms........................................................................................................................................................ 3
3.2.1
Operating and maintenance staff................................................................................................................................. 3
3.2.2
Competent person ....................................................................................................................................................... 3
3.2.3
Expert .......................................................................................................................................................................... 3
3.3
General notes and symbols ......................................................................................................................................... 3
3.4
Safety and health protection ........................................................................................................................................ 4
3.5
Owner's obligations...................................................................................................................................................... 5
Operating and Maintenance Staff ............................................................................................................................. 6
General Risks and Accident Prevention .................................................................................................................. 6
5.1
Risks and dangers ....................................................................................................................................................... 6
5.1.1
Mechanical hazards ..................................................................................................................................................... 6
5.1.2
Electrical hazards ........................................................................................................................................................ 7
5.1.3
Working on live components........................................................................................................................................ 7
5.1.4
Dangers caused by heat .............................................................................................................................................. 8
5.1.5
Dangers from noise ..................................................................................................................................................... 8
5.1.6
Danger from vibrations ................................................................................................................................................ 8
5.1.7
Dangers caused by fuels, auxiliary substances, lubricants and cleaning products ...................................................... 9
5.1.8
Danger from gases ...................................................................................................................................................... 9
5.1.9
Dangers from explosions ........................................................................................................................................... 10
5.1.10 Residual dangers....................................................................................................................................................... 10

5.1.11 Danger analysis ......................................................................................................................................................... 10
5.2
Behaviour after accidents (damage to property) ........................................................................................................ 10
5.3
Behaviour in the event of accidents (personal injury) ................................................................................................ 10
5.4
Handling old parts, fuels and auxiliary substances .................................................................................................... 11
5.5
Danger area............................................................................................................................................................... 11
Description of Structure and Function / Description of Process ........................................................................ 11
Technical Data (Dimensions, Weight, Operating Conditions) ............................................................................. 11
Transport and Storage ............................................................................................................................................ 11
Assembly.................................................................................................................................................................. 11
10
Electrical Installation ............................................................................................................................................... 11
11
Setting and Adjustment........................................................................................................................................... 12
12
Controls .................................................................................................................................................................... 12
13
Start-up ..................................................................................................................................................................... 12
13.1
Testing before start-up............................................................................................................................................... 12
13.2
Initial start-up ............................................................................................................................................................. 12
14
Operation.................................................................................................................................................................. 12
Page 1 of 14

A002
Version 6 (03/07)
14.1
Obligation to supervise .............................................................................................................................................. 12
14.2
Ban on operation ....................................................................................................................................................... 12
15
Shutting down .......................................................................................................................................................... 12
15.1
Disposal ..................................................................................................................................................................... 12
16
Measures in the event of unusual observations and operating faults ................................................................ 12
17
Care and Maintenance............................................................................................................................................. 13
17.1
Regular inspections (outside and inside inspections and water pressure tests) ........................................................ 13
17.2
Inspections by the operating and maintenance staff .................................................................................................. 13
17.3
Maintenance service contract .................................................................................................................................... 14
17.4
Teleservice ................................................................................................................................................................ 14
18
Replacement Parts................................................................................................................................................... 14
19
Lists and Tables....................................................................................................................................................... 14
Scope of the Operating Instructions
These Operating Instructions apply solely for parts and services supplied by Loos International. The supplier in question
must provide the appropriate operating instructions for parts of equipment on the boiler or system that were not supplied by
Loos International and carry out the necessary regulatory instruction of the operating and maintenance staff at the first startup.
If any changes are made to official regulations, Loos International does not provide any update service. The owner of the
boiler or system is obliged to inform the operating and maintenance staff of the latest version of the valid regulations
comprehensively and in good time.
We expressly point out that these Operating Instructions only contain the specific regulations issued by Loos International
for the operation of the boiler or system. Official regulations or requirements are quoted or mentioned only in passing, if at
all.
Use in Accordance with Regulations
A boiler or system or parts thereof that were supplied by Loos International may only be operated in accordance with the
present instructions. Any other use or operation is not in accordance with regulations and is therefore not allowed.
For the boiler system to be used in accordance with regulations, the owner must examine, on the basis of the valid
regulations, whether an operating permit is necessary for the boiler system to be installed and/or if the comments of local
authorities or supervisory organisations, as applicable, should be obtained.
If this is the case, the system may generally only be started up after the necessary documents have been submitted and
after the written notification from the supervisory authority has been obtained.
3
3.1
Safety
General
The components described in these Operating Instructions are manufactured according to the current state of the art and
meet the current safety regulations. If, according to the valid European regulations, a CE mark can be affixed, Loos
International confirms, for the free transport of goods within the European Economic Area, with the issue of the conformity
declaration and the affixing of the CE mark, that this system was manufactured in accordance with the valid European
directives.
Changes to this system may only be made with the express written permission of Loos International, since otherwise the
manufacturer's guarantee ceases to be valid. In addition, if changes are made independently to the system, compliance with
Page 2 of 14

A002
Version 6 (03/07)
the conformity declaration and the relevant directives can no longer be guaranteed. In this case, the person who made the
changes to the system is obliged to obtain a new operating permit if necessary and to prepare a new conformity declaration
if applicable
Loos International is not liable for damages which are caused by operating mistakes, operation not as directed, use not in
accordance with regulations, inexpert maintenance or lack of maintenance, or inexpert repairs or servicing.
3.2
3.2.1
Definition of terms
Operating and maintenance staff
Operating and maintenance works may only be carried out by people who are physically and mentally suited thereto and
sufficiently qualified and who have the necessary specialist knowledge. Proof must be provided of this qualification.
Depending on the regional regulations, it may be necessary for these people to have been given a special training for these
activities by an officially recognised body and to have to prove that this training was successfully completed.
Minors may not carry out these works. If this is necessary for training purposes, minors must always be supervised in
operating the system by suitable, experienced and reliable adults who have the necessary authorisation for this.
3.2.2
Competent person
A competent person is a person who, on the basis of his or her specialist training and experience has particular knowledge
in the field of boiler systems and is familiar with the relevant national health and safety regulations, accident prevention
regulations, guidelines and generally recognised technical rules (e.g. DIN, EN, ISO, corresponding national standards, VDE
(or corresponding national regulations) in both theory and practice. He or she should be able to test boiler systems and also
evaluate them according to the regional regulations.
Competent people are people who are expressly authorised by the owner to carry out inspections and who hold the
necessary qualifications. Regional regulations on training must be taken into account.
3.2.3
Expert
An expert is a person who, on the basis of his or her specialist training and experience has particular knowledge in the field
of boiler systems and is familiar with the relevant national health and safety regulations, accident prevention regulations,
guidelines and generally recognised technical rules (e.g. DIN, EN, ISO, corresponding national standards, VDE (or
corresponding national regulations) in both theory and practice. He or she should be able to test boiler systems and also
provide an expert's report on them according to the regional regulations.
Experts are people who are members of an organisation or a named department as defined in EU regulations or of a
supervisory organisation which is accredited and approved for this work according to the regional regulations.
3.3
General notes and symbols
The following symbols and notes are used in these Operating Instructions for safety notes. They warn against possible
personal injury or material damage or help you to simplify working procedures.
Danger! This symbol warns you of the immediate threat of a danger which could lead to the most severe physical
injury or death. These dangers can always occur if the operating or working instructions are ignored or not
followed precisely.
Warning! This symbol warns you of a possibly dangerous situation which could lead to severe physical injury or
death. These dangers can always occur if the operating or working instructions are ignored or not followed
precisely.
Attention! This symbol warns you of possibly dangerous situations which could lead to minor physical injury or
damage to the plant or other material damage. These dangers can always occur if the operating or working
instructions are ignored or not followed precisely. Failure to comply with these notes may invalidate the
guarantee.
Page 3 of 14

A002
Version 6 (03/07)
Important! This symbol warns of a possibly dangerous situation in which the boiler system or objects in the
surrounding area could be damaged.
Note: This symbol draws your attention to special points which will make your work easier.
Operating and maintenance staff: Maintenance and adjustment works which are marked by this symbol may be
undertaken by the trained user/operator of the machine (for definition, see section 3.2.1).
Competent/specialist staff: Maintenance and adjustment works which are marked by this symbol may only be
carried out by specially trained and instructed specialist staff with the corresponding mechanical and
electrical/electronic specialist knowledge and the necessary specific or special tools (for definition, see section
3.2.2).
Maintenance and adjustment works which are marked by this symbol may only be carried out by the
manufacturer of the system or by specially trained specialist staff who have been expressed authorised by Loos
International to do this work. If this instruction is ignored, any guarantee on the part of the manufacturer becomes
null and void.
Any failure to comply with safety instructions will result in danger to people or materials and can cause massive damage to
the environment and to the system. Failure to comply with safety instructions may lead to the loss of any right to claim
damages.
In detail, non-compliance may cause the following risks:
the failure of important system functions
the failure of prescribed methods of maintenance and repair
danger to people as a result of electrical and mechanical factors
3.4
Safety and health protection
The following provisions and regulations must be strictly followed to reduce the risk of personal injury and/or material
damage. In addition, the regionally valid requirements, regulations and conditions on safety at work and on the safe handling
of boiler system must be complied with absolutely.
Everyone who operates a boiler system must, for safety reasons, have read and also understood the present Operating
Instructions in full.
For the safe operation of the boiler system, the relevant health protection regulations, and the relevant state and other
regulations on safety at work must be strictly complied with.
The owner is obliged to provide all persons who work with systems or appliance which were supplied by Loos
International with the current version of the valid regulations in such a way that they are freely available to these persons
at all times.
The system may only be operated in accordance with regulations in compliance with these Operating Instructions.
The boiler, the boiler system and all parts must be used and operated in such a way that no danger may be caused by it
to people or the environment.
The effectiveness of operating and adjustment components may be not be impermissibly influenced or cancelled out.
All danger areas in the system are to be marked by the producer of the overall system by warning signs (pictograms).
These warning signs will indicate possible dangers. They form part of the Operating Instructions. They must always be
Page 4 of 14

A002
Version 6 (03/07)
kept in a clean, easily legible state. Warning signs which are damaged or no longer easy to read must be replaced
immediately. The meaning of every individual warning sign is explained precisely in the Operating Instructions.
3.5
Owner's obligations
The owner is obliged to prepare a set of operating orders on the basis of the present Operating Instructions and the
evaluation of the danger of this boiler or system.
The owner must ensure that the valid safety regulations, the official requirements and the notes in these Operating
Instructions are also actually complied with when operating the boiler or system.
The owner of the boiler or system must ensure that these Operating Instructions and/or the operating orders are always
available within reach, in full and in a readable condition at the workplace of the operating and maintenance staff and are
freely accessible at all times.
The owner may only allow the boiler or system to be operated by people who meet the requirements set out in
Section 3.2.1.
The owner must ensure that these people are so reliable that they can be expected also to actually carry out the tasks
assigned to them reliably and not to be under the influence of alcohol, medication, drugs or consciousness-limiting
substances when carrying out the operating and maintenance work.
The owner must ensure that work on the electrical components is only allowed to be carried out by trained and tested or
approved electricians. Work on gas equipment and components may only be carried out by correspondingly trained and
approved specialists.
The owner is obliged only to operate the boiler or system in a technically perfect condition. By means of corresponding
instructions and checks, the owner must ensure that the workplace is clean and tidy and that the areas by and around
the system are clean.
The owner must ensure that the operation of the boiler or system is monitored in a suitable way in accordance with the
official requirements.
The owner is obliged to inform the operating and maintenance staff in a suitable way about the regionally valid official
requirements and regulations on the operation of the boiler. He is also responsible for ensuring that tests, approvals,
records of the operation of the boiler or system (e.g. in the form of an operating log book), reports on operating faults etc.
which are required by official bodies (e.g. authorities) are carried out in good time and in accordance with regulations.
The owner of the boiler or system must ensure that the effectiveness of operating or adjustment components is not
affected. In addition, he must ensure that safety equipment and protective devices are always in a perfect condition and
in accordance with regulations. Safety equipment and protective devices may not under any circumstances be removed,
rendered inoperable or made ineffective in any other way.
The owner must that the safety equipment provided is fully functional and that this functioning capacity is checked at
regular intervals.
The owner of the boiler or system must ensure that everyone who works on the system possesses and also uses the
necessary or prescribed personal protective equipment.
All persons who work on the boiler or system must be informed of the location of the fire-fighting equipment available in
a suitable way.
The owner must always provided for sufficient exit routes in the event of an emergency (fire, leakage of medium,
development of flue gas, emergency stop, explosion). These emergency exit routes are vital. They must comply in full
with the regionally valid regulations, must be marked and may never be locked or moved.
The owner must, in accordance with the regional regulations, provide sufficient facilities and aids to be able to combat
any emergencies (fire, leakage of medium, development of flue gas, emergency stop, explosion) in their early stages. In
addition, he must ensure that a fire extinguisher that is ready to use is kept in an easily accessible location in the boiler
house in accordance with the regional regulations. This fire extinguisher must be checked regularly in accordance with
the regionally valid fire prevention regulations to ensure that it is in proper working order.
Page 5 of 14

A002
Version 6 (03/07)
The owner must, in accordance with the regional regulations, create sufficient ways of being able to report immediately
any emergencies (fire, leakage of medium, development of flue gas, emergency stop, explosion) and of being able to
obtain sufficiently qualified assistance.
Operating and Maintenance Staff
Obligations of the operating and maintenance staff:
Before starting work, you should read the owner's operating orders and the Operating Instructions in this file, especially
the safety and danger instructions. this applies in particular for people who are only occasionally employed on this
system.
Only use the boiler or system if you have been expressly instructed to do so by the owner.
Always take note of the safety and danger instructions affixed to the boiler and the system and in the Operating
Instructions.
Find out regularly about the possibilities that your workplace offers for being able to quickly report or fight any fires
occurring.
Find out regularly about the emergency exit routes available and check that these are not blocked.
Take note of the regionally valid statutory regulations on health protection and on protection of the environment (e.g.
when handling dangerous materials).
Always use the prescribed personal protective equipment (protective clothing etc.).
Your clothing must be such that it cannot be caught up by moving system components. Shirt and jacket sleeves must
either be buttoned up or turned over inwards.
Long hair should always be tied back. When working on the boiler or system, do not wear loose clothing or jewellery.
Always insert the end of neckcloths or scarves into your clothing.
You should not work on the boiler or system if you have taken medication which could adversely affect your
concentration or your reactions. Never operate the system whilst under the influence of alcohol or drugs.
Report faults immediately to the competent person or body; if necessary, switch off the boiler or system and secure
against being switched on again without authorisation.
All maintenance work that is not expressly authorised for the operator may only be carried out by persons with the
corresponding qualification.
General Risks and Accident Prevention
5.1
Risks and dangers
Despite being constructed in line with safety regulations, the operation of boilers or boiler systems always involves certain
risks and dangers. Loos International has, of its own accord, taken all measures and precautions to make its products as
safe as possible. Most operating faults or accidents are caused by incorrect operation or unsuitable operating conditions. In
the interests of your own safety, we ask you to follow the following safety instructions precisely. In the following, we point out
the main risks and dangers which may occur when operating a boiler or boiler system. The following list is not necessarily
complete, since individual operating conditions on which Loos International has no influences may cause additional risks
and dangers. Loos International cannot foresee or estimate these risks and dangers.
5.1.1
Mechanical hazards
Danger! Loss of consciousness and physical injury of varying severity may be caused by: parts that are flung out
e.g. during an explosion or after inexpertly executed maintenance or repairs to system components that are under
pressure.
Page 6 of 14

A002
Version 6 (03/07)
Protective measures:
Only operate the boiler or system in accordance with the Operating Instructions
Monitor the boiler or system regularly
Only operate the boiler with the permitted fuels and auxiliary substances
If firing components develop operating faults, following the relevant Operating Instructions precisely
Always observe the relevant safety regulations when carrying out maintenance and repair work on system components
that are under pressure. Before working on system components that are under pressure, you should depressurise and
secure these system components before starting the work.
Only allow maintenance, repair or servicing work to be carried out by specialists/competent people.
5.1.2
Electrical hazards
Danger! Electricity can cause fatal accidents. Cardiac arrest, ventricular fibrillation, arrhythmia and other injuries
may be caused by touching wires and live parts that are not insulated or not properly insulated and by inexpert
maintenance or repair work on electrical systems or equipment or parts thereof.
Causes:
e.g. contact with live and energised parts or immediate proximity to such parts
open, electrically conductive parts after damage to insulation
faulty execution of maintenance work
faulty or non-existent safety checks after maintenance work
installation of the incorrect fuses or improper repair (bridging) of fuses
Precaution: Maintenance and repair work to electrical equipment and live parts may only be carried out by an electrician
(according to the guidelines laid down by the VDE or comparable European or regionally competent institutions).
Protective measures in the case of work in a de-energised state:
Systems and system components on which maintenance and repair work has to be carried out must be disconnected
from the power supply before the work is started.
Systems and system components that have been disconnected from the power supply must be protected against being
switched back on again without authorisation and must be marked accordingly
Components that have been disconnected from the power must be checked for residual voltage/that they are not live
before the start of work.
Any residual voltage must be discharged according to the recognised rules of electrical engineering (earthing and shortcircuiting)
Adjacent live parts must be covered or safeguarded.
5.1.3
Working on live components

may be caused by work on live components. Electric shocks and arcing are possible. This requires particular
technical and organisational measures and to some extent special protective clothing (according to the
guidelines laid down by the VDE or comparable European or regionally competent institutions).
Work on live components may only be carried out for really compelling reasons. Compelling reasons could be:
There is a risk that people's lives or health could be endangered.
There is a danger of major damage in commercial terms.
Work on live components may ONLY be carried out by trained, approved electricians. If necessary, these persons must war
the special, approved protective clothing that is prescribed for such work. They may only use tools and equipment that has
been tested and approved for the corresponding voltage range.
Page 7 of 14

A002
Version 6 (03/07)
5.1.4
Dangers caused by heat

Danger! Boilers become very hot during operation. Although the boiler is very well insulated against heat loses,
individual system components may reach very high operating temperatures. Touching these components could
cause burns. If hot water or steam flows out of the boiler system, this can cause severe scalding. Contact with hot
burner components can also cause severe burns. When burner components are opened, any flames occurring
may cause clothing to catch fire.
Before touching any part of the boiler, burner or system, check, by carefully bringing the hand closer, whether increased
heat radiation might indicate that the surface is hot.
If necessary, wear suitable protective gloves.
Wear suitable protective clothing.
Stay as far away as possible.
When opening shut-off valves, make sure that no-one is standing in the path of any outlet openings.
When opening inspection openings or doors, always stand behind the inspection opening cover or the door so that you
can use the cover or door as a protective shield.
5.1.5
Dangers from noise

Warning! Noise can cause a loss of hearing (deafness), hearing difficulties, health problems such as loss of
balance and giddiness and cardiovascular disturbances. Noise can lead to a drop in people's attention levels. In
addition, noise can disrupt spoken communication between the operating and maintenance staff and between the
staff and other people. The perception of audible warning signals can be adversely affected or destroyed.
Causes:
Pulsation noise (< 0.2 s; > 90 dB(A))
System noises over 90 dB (A)
Burner noises
Faulty burner settings
Inexpert installation of system components added later
Suitable hearing protection (cotton wool, earplugs, ear covers, headphones) should be worn or carried so that they are
within reach at all times.
Burners must be correctly set by a specialist.
Possible sources of noise must be searched for and eliminated through the use of suitable measures.
Note: Unfavourable local conditions may cause the valid noise limits to be reached or exceeded. Because Loos
International generally has little or no influence on the individual noise situation on the spot, it is up to the owner
to carry out corresponding noise measurements and to oblige the operating and maintenance staff to wear
special personal noise protectors through the application of special operating orders.
5.1.6
Danger from vibrations

Warning! If people are constantly exposed to vibrations, this may cause health problems, and especially to
disturbances of the nervous system. It may also cause damage to buildings or adjacent systems and equipment.
Page 8 of 14

A002
Version 6 (03/07)
Causes: Vibrations in boiler systems are almost always caused by incorrect burner settings, dirt or inexpert installation.
Have the burner checked and if necessary reset by an expert. Determine the cause of the vibrations that are not due to
the burner.
Make sure that the relevant system components are properly installed or separated from the system as regards
vibrations through suitable structural measures.
5.1.7
Dangers caused by fuels, auxiliary substances, lubricants and cleaning products

Warning! Fuels, auxiliary substances, lubricants and cleaning products may contain constituents that are
hazardous to health. In particular, the inexpert use of these substances and products can cause the following: the
triggering of allergies, severe caustic burns if these substances and products come into contact with the skin,
severe damage to the mucous membranes, poisoning or burns to the respiratory tract if these substances and
products are swallowed or if vapours emanating from these substances and products are inhaled, long-term
health problems if these substances and products are inexpertly handled and stored.
Read the safety instructions on the packaging of these substances and products carefully before use and follow the
safety instructions given precisely.
Avoid skin contact with these substances.
Wear suitable protective clothing (e.g. gloves, apron, goggles, protective footwear).
If these substances and products come into contact with skin, clean the areas of skin affected carefully, remove any
residues with plenty of plain water and consult a doctor if necessary.
Remove any clothing soiled by these substances and products immediately and leave to air in a suitable location. Clean
the items of clothing in question, throw away if necessary.
Keep any rags that are soiled by these substances and products in suitable containers in accordance with regulations
and dispose of them ecologically.
If these substances need to be transferred to other containers, always use suitable funnels.
Only transfer chemicals in the open air or in well ventilated rooms. The prescribed protection and safety regulations
should be noted and followed precisely.
Attention! The leakage of fuels, auxiliary substances, lubricants or cleaning products may harm the environment.
Soil and water may become polluted. Accidents may be caused by people slipping or falling over if circulation
areas are dirty.
Handle fuels, auxiliary substances, cleaning products, fats and oils carefully.
Carefully close containers filled with fuels, auxiliary substances, lubricants or cleaning products.
Dispose of empty containers ecologically and in accordance with regulations.
Keep suitable binders on hand and use them immediately if necessary.
Remove any leaked fuels, auxiliary substances, lubricants and cleaning products immediately with suitable binders (e.g.
special cloths) and dispose of ecologically and in accordance with regulations.
5.1.8
Danger from gases

Warning! Gases (including flue gases) can explode or cause irritation of the respiratory tract, severe poisoning or
death from suffocation if they are inhaled or swallowed.
Page 9 of 14

A002
Version 6 (03/07)
Keep sources of fire away from gases. Comply with safety regulations when handling gases. These safety regulations may
vary, depending on the substance used. The owner is obliged to make available the regulations applicable for his operation.
When handling gases, personal protective equipment must be worn (e.g. suitable face masks, protective clothing, etc.).
5.1.9
Dangers from explosions

Danger! Danger from explosions. The operation of burner systems can, in extreme cases, cause explosions in
the burner room or in the flue gas ducting. The causes may include lack of maintenance, inexpert maintenance or
adjustment work on the burner or the inexpert installation or burner or flue gas ducting components. If fuels are
inexpertly handled, this may very well cause an explosion.
Comply absolutely with safety regulations on the handling of fuels and gases.
Only have work on gas installations, supply lines or system components carried out by specialist staff/competent
persons.
Carry out maintenance at the required intervals.
In the event of ignition faults, follow the burner manufacturer's Operating Instructions precisely.
Only have work on parts carrying fuel carried out by specialist staff/competent persons.
Do not switch the burner back on again after an explosion! The boiler must remain out of operation until a competent
person allows the boiler to be started up after an appropriate inspection. Loos International recommends that this inspection
is carried out by suitably trained customer service engineers from Loos International unless a supervisory organisation has
been called in.
5.1.10 Residual dangers

Residual dangers are particular hazards which cannot be eliminated even though the system has been in line with safety
requirements. These residual dangers cannot be obviously detected and may cause injuries or be a health hazard.
If unforeseen residual dangers occur, operation of the boiler or system should be halted immediately and the competent
person in charge informed. This person will then take any further decisions and do everything necessary to eliminate the
danger that has arisen. The system manufacturer should be informed if necessary.
5.1.11 Danger analysis

The owner must check, within the scope of the valid regional regulations, whether a danger analysis is required for the boiler
or the system and have this prepared if necessary by specialist staff/competent persons.
5.2
Behaviour after accidents (damage to property)
If the boiler or the system is damaged or if parts of the boiler, Economizer, superheater or walls of pressure vessels are
overheated, burnt out or cooled down so suddenly that they might have developed faults, the system must be shut down
immediately.
Incidents of this type must be reported immediately, in accordance with regional regulations, to the supervisory authority
and/or the competent monitoring organisation for systems of this type. The supervisory authority may call for an
extraordinary inspection to be carried out in individual cases in the event of accidents or for special reasons.
5.3
Behaviour in the event of accidents (personal injury)
In the event of accidents involving personal injury, the necessary first-aid measures must be taken immediately, medical
help sought and the nearest available manager informed. If necessary, the system must be shut down using the emergency
off switch.
In the event of burns, the areas of skin affected must be cooled down immediately and lastingly.
A suitable extinguisher should be used immediately on people who are on fire.
Page 10 of 14

A002
Version 6 (03/07)
If clothing catches fire, do not run away under any circumstances. Throw the person on the floor immediately and
extinguish all flames immediately by rolling the person back and forth.
Any accident in which a person has been killed or injured in connection with the operation of the system must be reported
immediately, in accordance with the regionally valid regulations to the competent supervisory authority and/or the competent
monitoring organisation.
5.4
Handling old parts, fuels and auxiliary substances
When handling fuels and auxiliary substances, suitable protective clothing should be worn which prevents or reduces
possible skin contact with these substances. Faulty old parts that have been removed must be sorted by material and
collected and forwarded for proper recycling. Leftover oils, fats, metering products, solvents or cleaning agents must be
placed, safely and ecologically, in suitable collector containers that comply with regulations, stored and disposed
ecologically in accordance with the local regulations.
5.5
Danger area
If a danger area is defined for the boiler or the system, no-one may step into the danger area during operation. The danger
area must be designated as such by the manufacturer of the overall system through the use of yellow/black markings, as
shown in the drawing.
Description of Structure and Function / Description of Process
Please read the Operating Instructions for the component in question.
Technical Data (Dimensions, Weight, Operating Conditions)
In the design of a product manufactured by Loos International, standard regulations (e.g. EN 12953, Pressure Vessel
Guidelines, AD 2000, factory standards, etc.) are applied. If an acceptance documentation is agreed, this may be taken from
the specific regulations used. Characteristics which limit the working life of the equipoment, such as max. possible cold
starts or corrosion factors will be taken into account in accordance with the regulations applied.
The technical data are fixed in the order confirmation. A copy of the technical data forms part of the delivery documentation
and is generally found in Register M. For further information, please consult the enclosed data sheets.
Transport and Storage
Assembly
10 Electrical Installation
Page 11 of 14

A002
Version 6 (03/07)
11 Setting and Adjustment

12 Controls
13 Start-up
13.1 Testing before start-up

In general, a boiler may only be started up if it has been tested to ensure that it is in a proper state as regards assembly,
installation, erection conditions and reliable function and approved.
The owner is obliged to check, on the basis of the regionally valid regulations, whether these tests have to be carried out by
a monitoring organisation or expert.
13.2 Initial start-up

The initial start-up of components that were supplied by Loos International may only be carried out by Loos International
staff or by persons who have been expressly authorised by Loos International in writing to carry out these activities.
14 Operation
14.1 Obligation to supervise
Regional regulations govern the obligation to supervise boiler systems.
The system must be started up and shut down by the operating and maintenance staff unless separate devices for the safe
automation of these processes are provided and have been approved by an approved monitoring organisation.
14.2 Ban on operation

A boiler system or parts thereof may not be operated if they show faults which could endanger persons working there or
third parties.
15 Shutting down
15.1 Disposal
If the system or parts thereof are finally dismantled, the dismantled parts must be sorted by material type and disposed of in
accordance with the regionally valid environmental protection regulations in such a way that the environment is not
damaged and precious resources are protected. As far as possible, these parts should be taken for environmentally
appropriate recycling.
16 Measures in the event of unusual observations and operating faults

Please read sections
5.2 Behaviour after accidents (damage to property)
5.3 Behaviour in the event of accidents (personal injury)
Page 12 of 14

A002
Version 6 (03/07)
17 Care and Maintenance

may be caused by touching wires and live parts that are not insulated or not properly insulated and by inexpert
maintenance or repair work on electrical systems or equipment or parts thereof.
Important! None of the components of the boiler system including all the attached components may be cleaned
with high-pressure cleaners, water jets or similar. If this is nonetheless done, it may cause failure and damage,
including subsequent damage especially to electrical, electronic and mechanical components.
17.1 Regular inspections (outside and inside inspections and water pressure tests)
Regular inspections should be carried out in accordance with the relevant Operating Instructions.
Operating Instructions covering regular
inspection
Shell boilers with
maximum permitted working pressure > 1 bar or
maximum permitted temperature > 120C
B006
Shell boilers with

maximum permitted working pressure 1 bar or
maximum permitted temperature 120C
B009
Shell boilers with

maximum permitted temperature 190C
B011
Quick steam generators
B008
The Overall Operating Instructions supplied for the specific order in question by Loos International only contain the
Operating Instructions necessary for the boiler supplied.
17.2 Inspections by the operating and maintenance staff

The time periods given in the check list and the operating log for maintenance works and regular inspections must be
complied with precisely. Written records must be kept of these maintenance works and inspections according to the
regionally valid regulations and the instructions laid down by Loos International. These records must be kept in accordance
with the regionally valid regulations. The precondition for any guarantee claim is that all prescribed maintenance work has
been carried out and recorded without omission in the operating logs.
Assignment of check lists and operating logs as a function of the boilers:
Steam generators
Hot water boilers
Check list
(Operating Instructions)
Operating log
(Operating Instructions)
Shell boilers
B001
L002
Quick steam generators
B005
L003
Heating boilers
B010
L005
Hot water boilers
B007
L004
The Overall Operating Instructions supplied for the specific order in question by Loos International only contain the
Operating Instructions necessary for the boiler supplied.
Page 13 of 14

A002
Version 6 (03/07)
17.3 Maintenance service contract

For proper, safe operation, regular maintenance must be carried out by specialist staff/competent persons in order to ensure
economical operation without breakdown. Regular maintenance will help your system retain its value and ensure the longterm, optimum availability of your system. In many countries, regular maintenance must be carried out by trained specialist
staff/competent persons and a regular inspection of the safety equipment on the boiler by experts is also required.
We therefore recommend that you conclude a maintenance service contract. Within the scope of this contract, specially
trained customer service engineers will take over the regular inspections and competently carry out all maintenance work on
the boiler. Our customers can obtain a quotation for a maintenance service contract by visiting www.loos.de or contacting
the relevant customer service engineer.
17.4 Teleservice
Using a modem, data from the boiler and system control are transmitted via a telephone line directly to Loos International.
Specialists:
prepare system analyses,
optimise regulating parameters,
provide support in the case of breakdowns
help with repairs and maintenance.
The solution of problems within the shortest possible time offer users considerable financial advantages and increase the
availability of the boiler system.
Teleservicing (remote servicing) is possible if the boiler system is fitted with Loos Boiler Control LBC and/or Loos System
Control LSC. Various service variants are possible, individually matched to the needs of the operator. Our customers can
obtain a quotation for a Teleservice Contract from www.loos.de or from the competent customer services engineer.
18 Replacement Parts
When repair and maintenance work is carried out, only original parts made by Loos International may be used and installed.
These original parts are specially designed and made for our boiler systems. The meet the high quality standards for Loos
International and offer safety and reliability. We expressly point out that spare parts that have not been examined and
approved by Loos International may not be used with this boiler system, since this would have a major adverse effect on the
safety and operability of the boiler system. Loos International cannot take any responsibility for installations of this type and
the resultant consequences. Changes made independently to the boiler system will invalidate any guarantee rights. Under
some circumstances, they may also invalidate any official permits that have been granted. This also applies if seals or
sealing paint applied at the factory are damaged or removed.
For spare parts orders or spare parts inquiries, please use the special ordering and inquiries form L006 After Sales Services
in Register L (Forms).
Alternatively, you can place your spare parts order or your spare parts offer online at www.loos.de / Kundendienst /
Ersatzteilversorgung (customer service / spare parts supply).
19 Lists and Tables

Page 14 of 14
Operation
Guideline on Water Characteristics

for heating boilers and hot water boilers
B004
Version 4 (10/09)
Contents
1
Use in Accordance with Regulations ....................................................................................................................... 1
Safety .......................................................................................................................................................................... 2
5.1
Dangerous situations.................................................................................................................................................... 2
5.1.1
Formation of deposits................................................................................................................................................... 2
5.1.2
Corrosion...................................................................................................................................................................... 3
Requirements for filling and make-up water and circuit water quality.................................................................. 3
6.1
Filling and make-up water 2) ......................................................................................................................................... 3
6.2
Circulating water .......................................................................................................................................................... 4
6.3
Notes on Tables 1 and 2 .............................................................................................................................................. 4
6.4
Addition of frost protection agents to circuit water ........................................................................................................ 5
Initial filling ................................................................................................................................................................. 5
Down times ................................................................................................................................................................. 5
Water investigation .................................................................................................................................................... 5
10
Measures in the event of unusual observations and operating faults .................................................................. 6
11
Guarantee notes ......................................................................................................................................................... 9
These Operating Instructions contain basic information. They apply in combination with the following operating instructions:
A002 Basic Safety Instructions
For the operation of the system as a whole, the operating instructions for the individual components are binding along with
the relevant statutory provisions and official requirements.
The specified limit values have been agreed with TV Sd and apply to hot water boilers and boilers made of non-alloy or
low-alloy steel. They are based on long-term experience and the binding safety minimum requirements of EN 12953 Part 10
and VdTV/AGFW Information Sheet TCh 1466 / FW 510 Edition 03/2004, on the reduction of:
RIsk of corrosion
Sludge waste and
Formation of deposits.
In so far as parts of the hot water boiler or heat consumer system need additional requirements, then the manufacturer of
the system shall specify this. During the planning of heating systems, the appropriate standards - in particular DIN 4751 and
Page 1 of 9

B004
Version 4 (10/09)
4752, the boiler room guidelines and all the relevant regulations should be observed. If there is any doubt, we would ask you
to contact us.
Safety
Please read the Operating Instructions:
5.1
Dangerous situations
During the operation of the boiler plant dangerous situations may arise as a result of operation. Damage can only be avoided
if these situations are recognised in good time and if the correct measures are taken immediately. The following list of
dangerous situations makes no claim to be complete, but is based on values from experience that have been gathered
through decades of observing our products. If other installations or system components are present, the measures that apply
for these system components must be coordinated with the manufacturer of these installations or components.
The operating staff must report any dangerous situations immediately to the supervisor responsible.
According to the regional regulations, damage to pressure-bearing walls of the boilers and if provided the which, as
a result of a danger to the operating staff or third parties, leads to a halt in operation must be reported to the competent
supervisory authority and/or monitoring organisation which is responsible for safety tests on the boiler system.
5.1.1
Formation of deposits
Danger! There is a danger of deposits forming. The formation of deposits can destroy the boiler. There is an
acute risk to life for everyone in the vicinity of the boiler from flying parts and from the hot medium (steam, hot
water). Extremely serious damage can be caused to the boiler by insufficiently prepared water, unsuitable dosing
agents or dirty condensate. Deposits should not be regarded as harmless. The thickness of the deposits is no
indication of their effect in restricting heat.
If deposits are observed on the water side, further operation of th boiler system is not allowed.
The boiler may only be started up again once the deposits have been removed and if an expert allows the boiler to be fired
up after a suitable test has been carried out. Loos International rcommends that this inspection is carried out by a suitably
trained service engineer from Loos International, an expert or persons who have been expressly authorised by Loos
International to carry out this work.
It is recommended that an experienced specialist company is employed to remove the coating and/or deposits.. If chemical
cleaning is required, this must be noted in the operating log.
Note: Boilers may only be cleaned with boiler scale solvents which are approved under regional regulations. The
regulations on safety and environmental protection must be strictly complied with. These regulations and
instructions are given on the cleaning product containers or in the corresponding safety data sheets. These data
sheets are available from the supplier of the cleaning product.
Page 2 of 9

B004
Version 4 (10/09)
5.1.2
Corrosion
Danger! Danger from corrosion. Corrosion can destroy the boiler. There is an acute risk to life for everyone in
the vicinity of the boiler from flying parts and from the hot medium (steam, hot water). Extremely serious damage
can be caused to the boiler by insufficiently prepared water, unsuitable dosing agents or dirty condensate.
If corrosion is observed on the water side, further operation of th boiler system is not allowed.
The boiler may only be started up again once the deposits have been removed and if an expert allows the boiler to be fired
up after a suitable test has been carried out and measures have been taken to repair the corrosion, or at least to prevent the
corrosion from spreading any further.
Loos International rcommends that this inspection is carried out by a suitably trained service engineer from Loos
International, an expert or persons who have been expressly authorised by Loos International to carry out this work.
6
6.1
Requirements for filling and make-up water and circuit water quality
Filling and make-up water 2)
Table 1: Requirements for filling and make-up water

Boiler design
Flame tube-fire tube boiler
Water chemical operation

Electrical conductivity in circuit water
Salty
[S/cm]
Column
General requirement
pH value at 25 C
Earth alkalis (total hardness)
1)
Low salt 1)
> 100-1500
> 30-100
30
Colourless, clear, free of insoluable matter

[-]
8.5-10.5
8-10.5
[mmol/l]
< 0.02
[ dH]
< 0.1
[mg/l]
< 0.1
Iron
[mg/l]
< 0.2
Copper
[mg/l]
< 0.1
Oil/grease
[mg/l]
<1
Oxygen (O2)
3)
8-10
Page 3 of 9

B004
Version 4 (10/09)
6.2
Circulating water
Table 2: Circuit water requirements

Boiler design
Flame tube-fire tube boiler
Water chemical operation
Salty
Electrical conductivity in circuit water
S/cm
1)
Low salt 1)
> 100-1500
> 30-100
30
Column
General requirement
Colourless, clear, free of insoluable matter
pH value at 25 C 4)
pH value
9.5-10.5
9-10.5
9-10
K S8.2 (p value)
mmol/l
< 0.5-5
0.1-0,5
mmol/l
< 0.02
dH
< 0.1
Oxygen (O2)
5)
Phosphate (PO4)
4) 5)
When oxygen binders are used
1)
< 0.02
< 0.05
< 0.1
mg/l
5-15
5-10
3-6
mg/l
5-10
5)
Soldium sulphite (Na2SO3)
6.3
mg/l
Notes on Tables 1 and 2

Low salt operation is advisble for:
Large pipe networks with lots of branches, such as in industrial or remote heating systems;
Longer periods of stagnation, also of parts of the heating network;
Greatly varying pressures and temperatures;
Systems with components made of various materials;
Operation without chemical oxygen binders (if necessary, in conjunction with partial flow overpressure degassing).
Operation with frost protection agents in a hot water system requires a particular method. The electrical conductivity limit
values do not usually need to be complied with. See Section 6.4.
2)
Usually, the filling water is a mixture of prepared make-up water from the circuit. Well-prepared, low-salt make-up water,
if necessary condensate, is required for low-salt operation.
3)
The guide value for oxygen is adjusted to automatically on boiling in the top-up tank (boiling degasser) and under
exclusion of air. The steam line for removing the vapour and toxic gases only needs to be open for make-up water
refilling, approx. 30 - 60 min. afterwards.
4)
Adjusting the alkalinity (pH value or KS 8.2):

For salty operation, the alkalinity is usually set automatically by the filling water composition. If this is not the case,
alkalify the water primarily using solid alkalis (trisodium phosphate or possibly addition of sodium hydroxide).
With low-salt operation, the pH value should be adjusted using trisodium phosphate or potassium phosphate.
Avoid ammonia.
If there are cupreous materials in the hot water network, the circuit water may not exceed pH 9.5.
5)
In permanent heating mode, the limit values are maintained automatically - oxygen binders are then not essential.
1)
Otherwise, physical methods see under and chemical agents are available.
A standard chemical agent is sodium sulphite. Film-forming aminos are not an oxygen agent. The use and type of the
Page 4 of 9

B004
Version 4 (10/09)
oxygen agent must be specified for each system.

With sodium sulphite in salty heating water, there should be an excess of 5...10 mg/l. Sulphide may occur in heating
networks, and has a corrosive effect on copper and copper alloys. The salt content of the water increases. There are no
hygienic or toxicological restrictions on sodium sulphite.
In heating water with a low salt content, the limit values for phosphate must be maintained, to avoid tension crack
corrosion do not go below the lower limit value concentration.
The use of other dosing agents and protective chemicals/inhibitors other than those specified should be agreed with
Loos International.
Important: When using oxygen binders or other protective chemicals the application regulations of the appropriate
manufacturer and suplier shall have sole validity. Damage to boiler systems caused by chemicals and insufficient
protective measures shall be outside the sphere of liability of the boiler manufacturer.
6.4
Addition of frost protection agents to circuit water
In some cases, a frost protection agent, e.g. on a base of monoethylene glycol or propylene glycol, is added to the circuit
water, in order to avoid freezing of the circuit water in the winter.
When using glycol-water mixtures, observe the following:
In conjunction with frost protection agents, it is often not possible to comply with the limit values for electrical
conductivity. Therefore use only completely desalinated water with a conductivity of < 10 S/cm as filling and make-up
water.
Due to their corrosion promotion properties, which are stronger than those of water, glycol-water mixtures may not be
used without the addition of corrosion inhibitors. However, these corrosion inhibitors must be contained in the frost
protection agent. Additional dosing agents may not be used!
Comply with the minimum concentration specified by the manufacturer of the frost protection agent, as, if not met, there
is the risk of insufficient inhibition. Also, always comply with the deadlines specified by the manufacturer for replacing
the frost protection agent.
Important! The mixing of frost protection agents changes the physical properties of the circuit water.
The effects on the heating system and boiler selection should, if necessary, be checked by Loos International.
Initial filling
Hot water systems may only be freshly filled with treated, at least softened, water, to which at least 50 g of trisodium
phosphate (20 % P2O5) should be added per 50 g. Low-salt water can, for example, be obtained from large power stations
by tanker.
Down times
To avoid corrosion during down times (during longer operational interruptions or delayed commissioning), conserve hot
water boilers, and if necessary the heating network, properly. For information on this, please refer to the operating manual of
the appropriate components and the operating manual G012 Wet and Dry Conservation.
Water investigation
Check the characteristics of the filling and make-up water and circuit water once a week.
Page 5 of 9

B004
Version 4 (10/09)
Important: The water samples must only be taken from the system during normal operation, i.e. not in the cold
state or in start-up operation.
For the analysis, a representative sample is necessary which, via a suitable cooling device (e.g. Loos water
sample cooler) allows the water to be tested to be cooled to 25 C. For instructions on taking the water sample,
see Operating Instructions E004 Water sample cooler module SCM.
Scope of the water investigations:
Filling and make-up water:
pH value or KS 8.2
Oxygen or oxygen binder
Circuit water:
pH value or KS 8.2
Oxygen or oxygen binder
Phosphate or alkalising agent
Electrical conductivity
Appearance
The results should be entered in the logbook L004 for hot water boilers or L005 boilers. The investigations of the other
values and additional parameters, such as iron, copper or sulphides, should be carried out, as far as is relevant, on a
monthly basis, and, if possible, the methods of analysis mentioned in EN 12953-10 applied.
Important! Should national requirements require more frequent or more comprehensive water investigations,
these shall have priority over the manufacturer's requirements.
Note: Only experienced specialist companies should be asked to supply and install water treatment systems or
water treatment devices. We have found that the support provided by the customer service units of these
companies and/or departments specialising in water chemistry to be very useful.
Note: When using frost protection agents in the first year of operation, carry out a water-side investigation of the
boiler every three months. If the result is positive, the investigation periods can be increased to the normal levels.

If anything unusual is observed and/or operating faults are displayed, the following table provides initial information on
repair:
Observation/Fault:
Turbid circuit water
Cause
Elimination of the cause
Hardness precipitation (earth alkali phosphates)
Adjust the water values according to the Circuit

Water table
By whom?
Determine the cause of the hardness
Page 6 of 9

B004
Version 4 (10/09)
Cause
By whom?
Partial water exchange (increase clarification rate)
Entry of corrosion products
Testing of additional water treatment
Use of unsuitable chemicals
Engage a specialist company
Observation/Fault:
Operator
Corrosion in the boiler, flue gas heat exchanger
Damage elimination: Repair of damaged heating surfaces, removal of coating by a specialist company
Cause
Improperly treated filling or make-up water
Testing of water treatment, for ion exchange plants,

trigger regeneration as necessary
By whom?
Adjust water treatment to different raw water values.

(Check and correct the throughput between two
regenerations)
Set a constant pressure in front of the water
treatment plant
Outside substance ingress into circuit water (oils,

greases, organic matter, acids, alkalis, hardness,
etc.)
Use a higher quality treatment method (e.g.

osmosis)
Operator
Plan for circuit water monitoring (conductivity,

turbidity).
Operator
Conductivity: Acids, alkalis, hardness, seawater

Turbidity: Oils, greases, milk, paints
Use of film-forming aminos in conjunction with saltfree or low-salt methods
Observation/Fault:
Precipitate film formation agent
Operator
Corrosion in the boiler, flue gas heat exchanger
Damage elimination: Build-up welding. Component replacement. This work may only be carried out by Loos International
or by personnel authorised by Loos.
Cause
Oxygen ingress during down times.
During down times, carry out wet and dry

conservation according to the operation manual
G012. Keep the system pressurised during shorter
down times.
By whom?
Page 7 of 9

B004
Version 4 (10/09)
Cause
Insufficient degassing of the filling and make-up

water
Testing of the thermal degassing (constant pressure

and temperature, sufficient vapour volume)
By whom?
Checking of the excess of O2 binder
Insufficient chemical dosing
Checking of the excesses according to the Circuit

Water table
Check the chemical dosing
Overdose of dosing chemicals
Checking of the excesses according to the Circuit

Water table
Check the chemical dosing
Use of unsuitable chemicals
Engage a specialist company
Acid/alkali ingress through water treatment (in the

case of regeneration with acid/alkali)
Checking of water treatment

etc.)
Plan monitoring of the circuit water (conductivity,

turbidity).
Operator
Operator

Increased Cu concentration in the circuit water
Remove cupriferous components
Operator
Keep the pH value in the circuit water between 9

and 10.5, see Table 2
Check the ammoniac dosing
Check the sulphide concentration
Page 8 of 9

B004
Version 4 (10/09)
Observation/Fault:
Corrosion in the hot water network
Damage elimination: Replacement of the corroded pipe sections

Cause
Oxygen ingress
Keep the system pressurised during down times.
By whom?
Find the causes for the oxygen ingress into the

system (e.g. gas-permeable plastics) and eliminate
them
Make lines in a corrosion-resistant material
Insufficient degassing of the filling and make-up
water
Operator
Testing of the thermal degassing (constant pressure

and temperature, sufficient vapour volume)
Checking of the excess of O2 binder

etc.)
Plan monitoring of the circuit water (conductivity,

turbidity).
Operator

11 Guarantee notes
The guarantee becomes null and void:
Use of film-forming aminos in conjunction with low-salt methods (osmosis, partial or complete desalination)
if dosing agents are used which are not listed in this guideline or not agreed with Loos International.
if the limit values for water characteristics are not fulfilled.
if the measured water values are not documented.
In the case of special operating requirements (e.g. reduced working pressure, high level of steam purity), the limit values
must be agreed between the operator and Loos International.
Important: If protective chemicals are used, the regulations laid down by the appropriate manufacturer and
supplier apply exclusively. Damage to boilers caused by chemicals or faulty protective behaviour is basically not
covered by the liability of the boiler construction company.
Page 9 of 9
Regular inspections for shell boilers

Maximum permitted working pressure greater than 1.0 bar or
maximum permitted temperature greater than 120C
B006
Version 6 (03/04)
Contents
1
Safety .......................................................................................................................................................................... 2
Operation.................................................................................................................................................................... 2
5.1
External inspection ...................................................................................................................................................... 2
5.1.1
General ........................................................................................................................................................................ 2
5.1.2
Inspection intervals ...................................................................................................................................................... 3
5.2
Internal inspection........................................................................................................................................................ 3
5.2.1
General ........................................................................................................................................................................ 3
5.2.2
5.3
Water pressure test ..................................................................................................................................................... 3
5.3.1
General ........................................................................................................................................................................ 3
5.3.2
5.3.3
Scope of the inspection ............................................................................................................................................... 4
5.3.4
Execution ..................................................................................................................................................................... 4
Measures in the event of unusual observations and operating faults.................................................................. 4
Replacement Parts .................................................................................................................................................... 9
These Operating Instructions contain important information regarding the prescribed regular inspection of shell boiler type
steam and hot water generators made by Loos International with a maximum permitted working pressure greater than
1.0 bar for steam boilers or a maximum permitted temperature greater than 120 C for hot water generators.
It also applies for any associated flue gas heat exchangers provided (Economizers) and superheaters manufactured and
delivered by Loos International.
The inspections also cover the directly and indirectly attached components which are required for the operation of the
system and the switchgear cabinet and burner if these modules were supplied by Loos International.
All other parts of the system which were supplied and installed by third parties are covered by the regulations issued by the
suppliers in question.
These Operating Instructions only apply in combination with the following Operating Instructions:
B002 Guideline on water characteristics for steam boilers
B004 Guideline on water characteristics for hot water boilers
For the running of certain tests and for behaviour in the event of operating faults, not only the relevant Operating Instructions
issued by Loos International but also the relevant statutory orders, official requirements and other regulations on the part of
the suppliers of other system components associated with Loos International boiler system must also be followed.
Page 1 of 9

B006
Version 6 (03/04)
Important! All the inspections and inspection periods given here are minimum requirements laid down by Loos
International for the safe operation of the boiler system.
Important! If a smaller number of inspections or other inspection concepts are usual throughout the country or
industry, these will be accepted by Loos International if the regionally competent supervisory authorities have so
far agreed to these.
Important! If the regional supervisory authorities lay down shorter inspection periods a higher number of
inspections or a wider scope of inspection, these must definitely be complied with.
Important! If the regional supervisory authorities require an official expert instead of a competent person, this
requirement must definitely be met.
Safety

Important! If the boiler system has to be shut down, the operating and maintenance staff must be suitably
informed of this. In addition, a sign is to be affixed to the system and to the switchgear cabinet if necessary which
expressly points out that the system has been shut down and is thus not operational. This sign should also state
the time when the system was shut down and the name of the person who is allowed to start the boiler system
up again or who may give the instructions for the start-up.
For a definition of the terms operating and maintenance staff, competent person and official expert, please read the
Operating Instructions:
For proper, safe operation, regular maintenance must be carried out by specialist staff/competent persons in order to ensure
economical operation without breakdown. Regular maintenance will help your system retain its value and ensure the longterm, optimum availability of your system. In many countries, regular maintenance must be carried out by trained specialist
staff/competent persons and a regular inspection of the safety equipment on the boiler by experts is also required.
We therefore recommend that you conclude a maintenance service contract. Within the scope of this contract, specially
trained customer service engineers will take over the regular inspections and competently carry out all maintenance work on
the boiler. Our customers can obtain a quotation for a maintenance service contract by visiting www.loos.de or contacting
the relevant customer service engineer.
Operation
The basic requirement for the proper, safe operation of the boiler system is compliance with the inspections and inspection
periods laid down regionally, nationally, internationally or by Loos International.
5.1
5.1.1
External inspection
General
The external inspection covers regular monitoring by means of visual examination, the observation of work sequences and
any functional tests.
The external inspection is carried out by a competent person.
Page 2 of 9

B006
Version 6 (03/04)
5.1.2
Inspection intervals
The interval for regular external inspections begins with the start-up of the boiler system, or 2 years after delivery from the
manufacturer's factory at the latest; the maximum interval between two inspections is one year unless regional or national
regulations specify a shorter period of time.
The deadline for the external inspection is considered to be met if this inspection is carried out during the course of the
calendar year in which the deadline expires.
If internal inspections are due at the same time, the external inspection should follow on after this inspection.
5.2
5.2.1
Internal inspection
General
For an internal inspection, the boiler must be shut down and at least partly emptied and partly cooled down.
During an internal inspection, the inside surfaces of the boiler are examined for possible damage. If wished and if
necessary, prevent measures which may be required on the basis of these observations may be taken. Because of the
pressure loads during operation, essentially welded seams and the surfaces inside the boiler must be examined.
There is no need to remove the insulation or any brick linings.
After each internal inspection, an external inspection must be carried out.
The internal inspection is carried out by a competent person.
5.2.2
The interval for regular internal inspections is maximum three years unless regional and/or national regulations prescribe a
shorter period of time. It begins with the start-up of the boiler system, or 4 years after delivery from the manufacturer's
factory at the latest.
If the deadline for the water pressure test is extended alternatively to a maximum of 12 instead of 9 years, the interval for the
regular internal inspection must be shortened to two years at most.
The inspection does not need to be carried out if the boiler is out of operation when the deadline passes. However, it must
then be carried out before the boiler is started up again.
If a boiler is out of operation for longer than two years, an internal inspection must always be carried out by a competent
person before it is started up again.
5.3
5.3.1
Water pressure test

General
The boiler must be shut down and cooled off for the water pressure test. If necessary, the boiler may be cooled to the
required temperature more quickly by draining it and carefully refilling it with cold water.
Caution! Danger of thermal shock. To prevent any tension cracks forming in the boiler wall, the temperature of
the boiler when cold water is added should not be reduced faster than 3 K/min.
It is not necessary to remove the insulation or any wall linings for the water pressure test.
The water pressure test is carried out by a competent person.
After the water pressure test, an internal and external inspection must be carried out.
5.3.2
The inspection interval for the regular water pressure test is nine years at the most, unless local and/or national regulations
require a shorter period of time.
If the deadline for the water pressure test is extended alternatively to a maximum of 12 instead of 9 years, the interval for the
regular internal inspection must be shortened to two years at most.
The inspection interval begins with the start-up of the boiler system, and no more than 10 years (or, in application of the
above exception provision) 13 years after delivery from the manufacturer. The intervals may be extended by a maximum of
Page 3 of 9

B006
Version 6 (03/04)
three months, provided the competent person is notified, if important operating reasons mean that it is difficult to carry out
the inspection at the end of the inspection interval.
The inspection need not be carried out if the boiler is not in operation when the interval expires. The inspection must
definitely be carried out before the boiler is started up again.
If the boiler is out of operation for longer than two years, a water pressure test must be carried out before it is started up
again.
5.3.3
Scope of the inspection
The regular water pressure test covers the boiler and the flue gas heat exchanger (economizer) and superheater (if
provided) positioned in the flue gas current from the firing.
5.3.4
Execution
Level of test pressure

The test pressure applied may not be higher than the test pressure for the first water pressure test. The test pressure
applied for the first time during manufacture is given on the manufacturer's plate and/or in the technical documentation.
With flue gas heat exchangers (Economizers), the level of the test pressure is the same as the level of the test pressure in
the associated boiler.
Applying and maintaining the test pressure
The test pressure must be monitored with a calibrated manometer.
The test pressure is applied in the presence of the competent person. The speed of the change in pressure may not be
more than 10 bar per minute up to approx. 75% of the test pressure and after this no more than 2 bar per minute.
The test pressure must be maintained constantly for half an hour. At the end of the half hour, the pressure should be
reduced slowly and then applied again as described above. After a second period of half an hour, the competent person will
start to test the components under pressure.
Requirements for the water
The water used for filling may not contain any impurities. Taking the operating conditions into account, the water may not
contain any components which could attack or change the surfaces of the parts to be tested. The temperature of the water
added may not exceed 50C during the inspection on the flue gas side.
At lower ambient temperatures, measures should be taken to ensure that no damage is caused by fractures due to thermal
shock, freezing or brittleness. Suitable measures are, for example, heating the installation room for a few days before filling
the boiler, slow filling with water which is not too different in temperature from the temperature of the material (< 20 K).
Examination of walls
Components under pressure must be examined by a visual inspection to detect cracks, impermissible changes in shape or
leaks. Wall linings and heat insulation should be removed to an appropriate extent only if there are justified reasons for
suspecting damage.
Measures in the event of unusual observations and operating faults
If unusual observations are made and/or defects found in valves or fittings or the equipment, the procedure described in the
Operating Instructions for the equipment should be followed.
If deposits are found on the water side, the procedure described in the following Operating Instructions should be followed:
The following table lists possible faults which could be found during an internal or external inspection and which are
generally found at the pressure hull. If faults are found, this table provides some initial hints on how to deal with them.
Page 4 of 9

B006
Version 6 (03/04)
Observation/fault:
Tears in weld seams on water side
Repair of fault: The faults are normally repaired by reboring and rewelding the cracks. Components may be patched or
partially replaced. These works may only be carried out by Loos International or staff authorised by Loos International.
Cause
Repair of cause
Unsatisfactory burner operation
Set performance control according to Operating

Instructions for performance control
Starting up frequently with cold feed water
Check feed water system according to Operating

Instructions E008, E009, E010 or E011
Use of non-approved added chemicals
Use approved chemicals according to Operating

Instructions B002
Starting up frequently from the cold state
Keep boiler warm
Unsatisfactory load assumptions
Avoid simultaneous load peaks from several

consumer units
By whom?
Reduce extraction
Lower load change speeds
Start up only with load limitation
Observation/fault:

Tears in weld seams at points in contact with fire in steam boilers
Cause
Repair of cause
Deposit on the water side
Use suitable boiler, infeed and make-up water
By whom?
Increase desalting rate or blow-down more often
Prevent foreign matter from entering the

condensate

Page 5 of 9

B006
Version 6 (03/04)
Cause
Repair of cause
By whom?
Avoid frequent burner cycles
Avoid switching the secondary boilers on and off too

frequently
Unsatisfactory load assumptions
Avoid simultaneous load peaks from several

consumer units
Reduce extraction
Lower load change speeds
Starting up frequently with cold feed water
Observation/fault:
Check feed water system according to Operating

Instructions E008, E009, E010 or E011
Tears in weld seams at points in contact with fire in hot water boilers
Cause
Repair of cause
Deposit on the water side
Use suitable boiler, infeed and make-up water
Starting up frequently from the cold state
Keep boiler warm

By whom?
Avoid frequent burner cycles
Avoid switching the secondary boilers on and off too

frequently
Lack of flow through boiler
Ensure minimum throughput with burner operation,

see contract
Page 6 of 9

B006
Version 6 (03/04)
Observation/fault:
Deposits on flue gas side
Repair of damage: Have boiler cleaned on flue gas side by specialist staff
Cause
Repair of cause
Incorrect burner setting
Correct burner setting

Wrong fuel
Use fuel according to contract
Insufficient boiler house ventilation
Clear intake and outlet openings
Outlet blockages in flue gas system
Adjust flue gas system, clean if sooted up
Observation/fault:
By whom?
Corrosion on flue gas side
Repair of fault: The damage is generally repaired by reboring and rewelding local material corrosion. If necessary, smoke
tubes or flue tubing can be replaced or components patched or partly replaced. These works may only be carried out by
Loos International or staff authorised by Loos International.
Cause
Repair of cause
Boiler started up and shut down too frequently (dew

points crossed too frequently)
Keep boiler in operation longer, keep warm if nec.

Sulphur content of fuel too high temperature falls

below acid dew point
Use fuel according to contract
By whom?
Disable eco-operation or use feed water preheating
Increase boiler return flow temperature
Feed water temperature too low falls below acid

dew point (with steam boilers)
Test feed water system according to Operating

Instructions E008, E009, E010 and E011
Return flow temperature too low falls below acid

dew point (with hot water boilers)
Check return flow temperature control
Aggressive intake air polluted by chemicals
Change intake air supply to burner
Page 7 of 9

B006
Version 6 (03/04)
Observation/fault:
Corrosion on water side
Repair of fault: The damage is generally repaired by reboring and rewelding local material corrosion. If necessary, smoke
tubes or flue tubing can be replaced or components patched or partly replaced. These works may only be carried out by
Loos International or staff authorised by Loos International.
Cause
Repair of cause
Frequent start-up with cold feed water (with steam

boilers)
Test feed water system according to Operating

Instructions E008, E009, E010 and E011
Insufficient addition of chemicals
Follow Operating Instructions B002
Thermal feed water system not working properly (in

steam boilers)
Follow Operating Instructions E008, E009, E010

and E011
Use of non-allowed or unsuitable additional

chemicals
Use other products
Insufficient preservation when idle
Follow Operating Instructions C008
Make-up volumes too large with insufficient

treatment or metering (with hot water boilers)
Seal system, add chemicals according to Operating

Instructions B004 and/or B010
Observation/fault:
By whom?
Sludge collects at the bottom of the boiler
Repair of damage: Have the sludge removed from the boiler by the operating and maintenance staff
Cause
Repair of cause
Insufficient blow-down operations
Increase blow-down rate
Unsuitable boiler, feed or make-up water
Use suitable boiler, feed and make-up water
Addition of too many film-forming chemicals
Add additives (if allowed by Loos in the first place)

according to manufacturer's instructions
By whom?
Page 8 of 9

B006
Version 6 (03/04)
Observation/fault:
Peeling at the base of the boiler
Repair of damage: Have the deposits analysed and removed by a specialist company
Cause
Repair of cause
Hardness and/or silicates in water
Observation/fault:
By whom?
Deposits and discolouration on water side
Repair of damage: Have the deposits analysed and removed by a specialist company
Cause
Repair of cause
Hardness and/or silicates in water
Foreign matter in water (e.g. oils, fats, milk)
Install devices to monitor returning condensate or, if

these already exist, check function
Observation/fault:
By whom?
Grooves and impressions in smoke tubes on boilers with rotational flow devices
Repair of fault: The damage is generally repaired by welding the grooves. These works may only be carried out by Loos
International or staff authorised by Loos International.
Cause
Repair of cause
Deposits on water side
Repair water treatment plant
Use of unsuitable additional chemicals
Use chemicals recommended by Loos
Unsatisfactory burner behaviour
Adjust burner setting
By whom?
Replacement Parts
After opening the inspection openings on the steam and water sides, replace the seals in question.
K022 Inspection openings (steam and water sides)
To order replacement parts, please use the After-Sales Service order form L006 supplied by Loos International, giving the
factory number, product type and order number.
Page 9 of 9
Check list
for Hot Water Boilers
B007
Version 2 (06/05)
Contents
1
Care and Maintenance ............................................................................................................................................... 1
Care and Maintenance
Following, the minimum operating, maintenance and test requirements for the boiler system will be listed in the form of a
checklist by the operating and maintenance staff.
The inspection intervals listed below are minimum requirements set by Loos International. The inspection intervals must be
defined on the basis of the operating conditions and the water treatment products used.
Explanation of symbols:
Observation (O) Observation of abnormal noises, smells or other noticeable factors
12 months
6 months
3 months
1 month
1 Week
Operating, maintenance and testing work
3 days
Function test (F) Testing the functional behaviour of equipment parts, incl. observation
Test
Boiler
Safety valves
Filling testing device
Emptying and Blow-down device
Armatures
Pipes
Start *)
F
Functioning, free passage
Functioning and sealing,

availability auxiliary power - if
required
Sealing
Niveau limiter
Lower to switching poing
Flow monitor
Operate to switching point
Pressure indicator respectively temperature

indicator
Zero point check respectively

comparativce measurement,
free passage connecting pipe
Temperature controller
Monitor switching points;

comparative measurement
Page 1 of 3
Check list
B007
Feed and circulation devices
Test
Operate to switching point, free

passage connecting pipe
F
F
Sealing, possibly retighten
Short-term switching
Analytical monitoring, observe
operating manual B004
Feed water, boiler water respectively circuit water

Devices for monitoring boiler water for ingress of
foreign materials
12 months
6 months
Inspection openings
3 months
1 month
Pressure limiter respectively temperature limiter
1 Week
Operating, maintenance and testing work
3 days
Version 2 (06/05)
Function
F
Back-up battery Programmable Controller C7-633
Changing the back-up battery
Firing unit
Flue gas valve limit switch
Control element for air and fuel (network)
Combustion air blower, ignition and/or cooling air

blower
Air pressure volume display and air pressure

monitor
Fuel shut-off devices
Function
Free movement, check
switching points
Quiet running, power

transmission
F
Free movement and clear

opening of connecting pipe
Free movement and leaktightness, availability of

secondary energy if necessary
Fuel pressure display
Zero-point monitoring or
comparative measurement,
clear opening of connecting
pipe
Fuel safety shut-off device in front of burner
Free movement, Leak-tightness
Leak-tightness monitor with gas valves
Function
Ventilation of fire areas and flue gas lines
Function
Ignition
Noises
Flame monitoring
Assessment of combustion
Assessment of fire areas and flue gas tubing
If sensor turns dark

F
Flue gas measurement
Check
Page 2 of 3
Check list
B007
Version 2 (06/05)
Firing unit
Emergency switch
Function
If defects are found, the foreman should be informed and Operating Instructions A002 followed.
*) Note on starting up the safety valve:
To test the boiler safety valve, the firing is switched off and the boiler water is cold. The supply and removal lines to the
boiler are closed. Using the hand pump, the boiler pressure is increased until it reaches the safety valve trigger pressure.
After the safety valve is triggered, the pressure in the boiler is lowered to 0 bar.
Page 3 of 3
Boiler and
Boiler components
Operating instructions
Lining of the front reversing chamber

for Shell Boilers
C005
Version 1 (01/09)
Contents
1
Safety .......................................................................................................................................................................... 1
Technical Data (Dimensions, Weight, Operating Conditions)................................................................................ 2
Assembly .................................................................................................................................................................... 2
7.1
Pre-cleaning and preliminary works ............................................................................................................................. 2
7.2
Applying the adhesive .................................................................................................................................................. 3
7.3
Affixing the insulation ................................................................................................................................................... 4
Replacement Parts ..................................................................................................................................................... 6
C007 Closures on the firing and flue gas sides
The front reversing chambers (chamber and door) of the boiler series UL-S, ZFR, UT-H and UT-HZ are made in two layers
with thermal insulation mats. This means that the surface temperatures, the radiation losses and the boiler house
temperatures are lowered.
Safety
Page 1 of 6

for Shell Boilers
C005
Version 1 (01/09)
The thermal insulation mats consist of glass needle mats/needle-punched web made from several mats needle-punched to
each other. The mat width is approx. 1000 mm and the mats are around 20 - 25 mm thick per layer.
Threaded pins M5x50 and clips with suitable tapped holes are used to secure the thermal insulation mats.
The thermal insulation mats are non-combustible.
The thermal insulation mats do not contain any toxic or hazardous substances or compositions. They are neither
carcinogenic nor harmful to health and therefore, they are not subject to labelling requirements.
Humidity caused by the formation of condensate during start-up does not influence the insulating qualities of the mats after
drying.
The thermal insulation mats have an infinite durability. They only need to be replaced in case of damage.
The high-temperature adhesive is based on aluminium silicates.
7
7.1
Assembly
Pre-cleaning and preliminary works
Caution! Before repairing or attaching the insulation, the boiler should be cooled down to room temperature
(< 40 C) so that the adhesive does not harden too quickly and the competent persons who are carrying out the
assembly work are not in danger of being burned.
All dust and grease must be removed from the surfaces of the chambers and doors to be glued (dry wipe or wash down with
cleaning product) so that the adhesive can stick properly.
Before the thermal insulation mats are stuck in, the threaded pins to secure the mats must be welded on. A bolt welding unit
is recommended for affixing the threaded pins, but is not absolutely essential.
The threaded pins with clips are positioned max. 100 mm to the left and right of each butt joint in the upper thermal
insulation mat on the flue gas side, with a distance of max. 400 mm between them.
The following table applies for smooth large areas (no threaded pins and clips are necessary for the side and lower
reversing chamber walls, unless there are problems here):
Position of threaded pins and clips to hold the insulation mats in place
Boiler type
Number
Position
Reversing
chamber wall,
top
Reversing
chamber door
Reversing chamber wall,

top
Reversing chamber door
UL-S 1250 - 5000

UT-H 820 - 3270
Page 2 of 6

for Shell Boilers
C005
Version 1 (01/09)
Boiler type
Number
Position
Reversing
chamber wall,
top
Reversing
chamber door
Reversing chamber wall,

top
UL-S 6000 - 12000

UT-H 3950 - 7850
UL-S 13000 - 18000

5
UT-H 8500 - 11800
6
UL-S 22000 - 28000
6
UT-H 14400 - 18300
ZFR 20000 - 55000

6
UT-HZ 13000 - 38000
7.2
Applying the adhesive

Caution! Before repairing or attaching the insulation, the boiler should be cooled down to room temperature
(< 40 C) so that the adhesive does not harden too quickly and the competent persons who are carrying out the
assembly work are not in danger of being burned.
The adhesive must be applied to the metal in sufficient quantity on one side and in strips. The adhesive strips can be applied
horizontally or vertically and should be approx. 150 mm wide in each case. Adhesive tape must be available on the edges.
When fibre mats are to be glued to fibre mats, on the other hand, it is essential that the adhesive is applied over the full
surface. The reasons for this are the different coefficients of expansion of steel and the hardened adhesive which can, if the
adjoining surfaces are too large, cause tensions on hardening and thus to the loosening of the adhesive.
A triple toothed spatula is recommended for application.
Note: The adhesive is dry on the surface after about 1 hour and, with an adhesive thickness of approx. 1-2 mm,
hardened after about 2 hours. The air humidity, temperature and thickness of the layer of adhesive will have a
corresponding effect on times.
Page 3 of 6

for Shell Boilers
C005
Version 1 (01/09)
7.3
Affixing the insulation
The two layers of the thermal insulation mats should be glued if possible with the butt joints offset by at least 100 mm in a
cross-jointing pattern (especially at doors).
Since, with normal operating temperatures, the mat can be expected to shrink by 0.4 - 0.5% (5 mm/1 m length), an
allowance of approx. 1 cm should generally be made at the mat joint (i.e. to allow for the shrinkage, the mats must be slightly
stacked when they are installed so that they then adjoin each other precisely).
The mats must be affixed on the reversing chambers on the door side in such a way that when the doors are closed, the
mats provide a closed insulation surface inside (see Figure 1).
Figure 1: Front reversing chamber - view of lower section

Once they have been glued in, the mats are secured at the door and at the reversing chamber cover with threaded pins and
clips. (see table in chapter 7.1).
to the ends in operation (see Figure 1 and 2). Where the mats join between the door and the reversing chamber, the ends of
the insulation should be coated thinly with the adhesive flush with the frame so that the edges do not fray if the doors are
opened repeatedly (see Figure 1). If the mats are bent over for a short distance at the transition to the door, these must be
coated thickly so that the shape is maintained. Care must be taken to ensure that the adhesive joints are round (see Figure
2)
Page 4 of 6

for Shell Boilers
C005
Version 1 (01/09)
Figure 2: Front reversing chamber - view of join with door frame
Note: The adhesive must be left to dry for at least 8-10 hours, depending on air humidity, temperature and
thickness of application and with the reversing chamber door open before the boiler can be used again, so that
the adhesive does not harden too quickly, thus preventing the door mat from sticking to the adhesive on the
reversing chamber side.
A visual inspection must be carried out as part of the regular inspection.

B006 Regular inspections for shell boilers

(Maximum permitted operating pressure 1 bar or maximum permitted temperature 120 C)
An inspection by a Customer Service Engineer only needs to be carried out if there are external signs of damage (see
Table).
Page 5 of 6

for Shell Boilers
C005
Version 1 (01/09)
Observation/Fault:
Hot areas near the front reversing chamber(> 85C in door area)
Cause
Repair of cause
By whom?
Loosening of thermal insulation mats
Repair smaller areas by gluing down again

Completely re-line larger areas
Observation/Fault:
Discoloration of front reversing chamber
Cause
Repair of cause
By whom?

Observation/Fault:
Faults in burner operation or change in burner behaviour
Cause
Repair of cause
Thermal insulation mats are coming loose and

blocking one or more pipes
By whom?
Replacement Parts
When ordering replacement parts, please use the following material numbers:
Material number
Designation/object
Quantity
011629.1
Thermal insulation mat 25 mm x 1000 mm
Length or area in m depending on boiler size and

requirement
007456.1
High-temperature adhesive
Quantity in kg depending on boiler size and

requirement
011650.1
Threaded pins M5x50
see table in chapter on Assembly
011651.1
Matching clips for threaded pins M5x50
see table in chapter on Assembly
Page 6 of 6
Burner and flue gas side inspection openings

for shell boilers with lateral flame tube
C007
Version 5 (11/08)
Contents
1
Safety .......................................................................................................................................................................... 2
Description of Structure and Function / Description of Process ........................................................................... 2
6.1
Rear flame tube inspection opening ............................................................................................................................. 2
6.2
Front reversing chamber .............................................................................................................................................. 3
6.3
Sight hole ..................................................................................................................................................................... 3
6.4
Flue gas side inspection openings on flue gas chambers and economizers ................................................................ 4
Transport and Storage............................................................................................................................................... 4
Start-up ....................................................................................................................................................................... 4
8.1
Inspection of seals on the front reversing chamber door.............................................................................................. 4
8.2
Inspection of the seals on flue gas side inspection openings ....................................................................................... 4
10
10.1
Inspection of thermal insulation.................................................................................................................................... 7
11
For the cleaning and inspection of furnaces and flue gas lines, the boilers are provided with suitably dimensioned inspection
openings or doors.
On the basis of the sometimes very high temperatures which occur in this area, the care and replacement of the sealing and
thermal insulation elements used here require special attention. Seals or spare parts for burner-side inspection openings
which are supplied by Loos International may only be installed at the corresponding openings, since they have been
calculated and designed specially for these products. Any other use is not in accordance with the intended purpose and is
therefore not allowed.
Page 1 of 7

C007
Version 5 (11/08)
Safety
Seals that have been removed must be disposed of according to the regionally valid environmental protection regulations so
that they cause no danger to people or the environment.

Danger! As a result of operation, high temperatures may occur at inspection openings which may cause burns.
In addition, leaking or faulty seals may cause flue gases to leak out, which can also cause burning. In this case,
the boiler system must be turned off immediately.
The inspection and viewing openings allow the flue tubing to be inspected and cleaned inside.
Caution: Before opening inspection openings, the burner must be switched off and the fuel lines securely closed
off.
6.1
Rear flame tube inspection opening
The inspection opening for the flame tube is on the back of the boiler at the flame tube end. On the inside of the cover, the
thermal insulation is fixed in several layers firmly to the cover. The total weight is about 80 kg.
For the inspection of the furnace and for cleaning purposes, nuts (M16) must be loosened and the inspection cover
removed. The complete component can be pulled out by the handles. For removal and re-installation, suitable lifting
equipment, e.g. forklift truck, must be provided, or a frame provided up to the lower edge of the cover.
The seal (5) is firmly glued to the inspection cover, which means that the seal does not need to be changed after the
inspection opening has been dismantled. When the inspection cover is replaced, care must be taken to ensure that the
cover with the thermal insulation material is pushed straight into the inspection opening.
Warning! Injuries may be caused during removal and replacement by the cover falling down.
To secure, the washers must be put back in place and the nuts tightened evenly crosswise (maximum torque of 80 Nm).
Page 2 of 7

C007
Version 5 (11/08)
Flame tube cover
Inspection cover
Flame inspection hole
Internal thermal insulation
Sealing
Fixing nut
Figure 1: Flame tube inspection opening
6.2
Front reversing chamber
The screwed, swivel door on the outer reversing chamber on the front end of the boiler is used for the flue-gas cleaning and
inspection of the smoke tubes. On the inside, the door is provided with thermal insulation mats. These reduce the surface
temperatures of the component, radiation losses and the boiler house temperatures.
To open the door, the nuts M16 must be loosened and the washers removed.
The sealing against the smoke gas area is by means of a sealing cord inserted in the reversing chamber frame. Before the
door is closed, the sealing must be checked and replaced if necessary (see Chapter 8.1).
After the door has been closed, the washers must be replaced and the nuts tightened evenly, alternating crossways
(maximum torque: 80 Nm).
6.3
Sight hole
To observe the shape of the flame and the burn-out rate during burner operation, a closable flame sight hole is provided per
flame tube. This is located in the rear flame tube inspection opening.
To protect the glass from soiling and excessive temperatures, a hand-operated damper, operated from the outside, is
provided, which allows a clear view into the furnace when opened. The flame inspection hole may only be opened briefly to
observe the flame. After the flame has been inspected, the lame inspection hold must be closed again to prevent the glass
from being soiled or damaged by the effects of temperature.
The burner must be switched off for cleaning purposes. The locking screw can then be loosened and the glass removed.
When re-assembling, the seals in front of and behind the glass must be replaced and the locking screw tightened o that the
smoke gas cannot leak. If the screw is not tightened enough, it may happen that gas comes out between the sealing
surfaces, which can then lead to overheating in the entire area of the sight hole; this may even cause the flame sight hole to
be destroyed, with the consequent risk of damage to component parts attached to the boiler.
If work is being carried out on the hand-operated damper, care must be taken to ensure that the shaft passageway is as tight
as possible, which will prevent any gas from coming out through the shaft opening.
Page 3 of 7

C007
Version 5 (11/08)
6.4
Flue gas side inspection openings on flue gas chambers and economizers
According to the type of boiler there are further flue gas side inspection openings on the rear of the boiler on the flue gas
chambers or on the rear of the economizers, which serve for flue gas side cleaning and inspection.
To open the flue gas side inspection openings, any insulation present must be removed, the nuts loosened and any washers
removed.
A glued sealing cord seals the opening to the flue gas chamber. The seal should be checked and replaced if necessary
before closing the flue gas side inspection openings.
(see chapter 8.2).
After closing the flue gas side inspection openings, any necessary washers must be put back in place and the nuts tightened
evenly diagonally (maximum torque of M12:30 Nm).
Because of the residual moisture in brick linings after the manufacturing process, care must be taken to ensure that
transport and storage are frost-free in order to prevent damage from frost (cracks, flaking).
Start-up
C003 Shell Boilers for the production of saturated and superheated steam
C014 Shell Boilers for the producing of hot water

For safety reasons, the first start-up should be carried out solely by Loos International or by specialist staff
authorised by Loos.
Because of the residual moisture in the brick linings after the manufacturing process, water vapours may form in the brick
lining material if warming up is too fast, and these may not be able to escape through the pores available if heating up is too
rapid. This may cause flaking of the stones (see also Operating Instructions C003/C014 Shell boilers, Chapter
Commissioning).
8.1
Inspection of seals on the front reversing chamber door
The sealing of the front reversing chamber door is provided by sealing cord. Because of the temperature stresses, the
sealing cord hardens after a certain operating time and loses its elasticity. It is therefore necessary, after initial
commissioning and after replacement of the sealing cords, to tighten the reversing chamber doors evenly, alternating
crossways, using a ring wrench. After a week in operation, the doors must be tightened again. To achieve leak tightness, it is
important to tighten the screws evenly, which is only possible by moving crossways each time a screw has been tightened a
little; the amount of tightening torque is not the deciding factor.
When inserting new sealing cords, make sure that the overlap is sufficient by cutting the sealing cord ends at an angle.
In addition to this the sealing cord must be adequately wrapped with adhesive tape before cutting so that the cord does not
fray at the cut ends.
Caution: If the medium leaks out, this may cause injury. Sealing cords which have been installed for more than
six months must basically be replaced once the doors are opened.
8.2
Inspection of the seals on flue gas side inspection openings
The flue gas side inspection openings are sealed by means of a sealing cord. Because of thermal stress, the sealing cord
hardens after a certain operating time and loses its elasticity. It is therefore necessary after initial commissioning and after
replacement of the sealing cords to tighten the inspection openings on the flue gas side evenly, alternating diagonally, using
a ring wrench. After a week in operation, the openings must be tightened again.
Page 4 of 7

C007
Version 5 (11/08)
To achieve leak tightness, it is important to tighten the screws evenly, which is only possible by moving crosswise each time
a screw has been tightened a little; the amount of tightening torque is not the deciding factor.When inserting new sealing
cords, a sufficient overlap must be ensured (at least 30mm and the overlap on top).
The sealing cord itself is glued with an industrial glue (e.g. Sikaflex) to prevent shifting of the cord during closing.
Caution: If the medium leaks out, this may cause injury. Sealing cords which have been installed for more than
six months must basically be replaced once the doors are opened.
repair:
Observation/fault:
Seal slips out
Cause
Repair
Excessive tightening required at start-up
Insert new seal
Seal not positioned in the middle
Adjust seal and stick in place if necessary
Observation/fault:
Leaks when boiler heats up
Fault
Repair
Nuts not tightened after start-up
Tighten nuts; it may even be necessary to insert a

new seal
Unsuitable sealing surface
Clean sealing surface
Incorrect installation of sealing cords
Insert seal again
Observation/fault:
By whom
By whom?
Moisture leaking out
Fault
Repair
Condensation occurring in start-up state
Take boiler into operating state
By whom?
Condensation (air intake openings in the area of the Move air intake openings
reversing chamber door, so that cold fresh air
passes by warm boiler doors)
Page 5 of 7

C007
Version 5 (11/08)
Observation/Fault:
Hot areas near the front reversing chamber(> 85C in door area)
Cause
Repair of cause
By whom?
Observation/Fault:
Discoloration of front reversing chamber
Cause
Repair of cause
By whom?
Observation/Fault:
Faults in burner operation or change in burner behaviour
Cause
Repair of cause
Thermal insulation mats are coming loose and

blocking one or more pipes
Observation/fault:
Vibrations at front reversing chamber
Fault
Repair
Vibrations or pulsation triggered by the burner
Optimise burner setting
Observation/fault:
By whom?
By whom?
Faulty brick lining (flaking, cracks)
Fault
Repair
Frost damage
Replace brick lining
Non-compliance with required boiler start-up times

according to Operating Instructions C003/C014
Shell boilers, Chapter Commissioning
Vibrations or pulsations triggered by the burner
Optimise burner settings
By whom?
Page 6 of 7

C007
Version 5 (11/08)
Flame too long; flame burning onto brick lining
Optimise burner settings; if necessary replace or

modify flame head

Burner and flue gas side inspection openings must be checked at least every three months and during commissioning and if
there is any suspicion of leaks. Covered inspection openings must be revealed first. Otherwise, during the maintenance,
attention should be paid to the proper positioning and the inspection openings must be checked for unusual phenomena.
After leaks, inspections must be carried out more frequently.
10.1 Inspection of thermal insulation

To protect against heat and temperature, various different thermal insulation materials are used, depending on the
temperatures which occur. In the area of high temperatures, e.g. in the flame tube, extremely fire-resistant cast materials are
used which have a sufficient surface resistance for the fuels used.
Because of the residual moisture in the stone after the manufacturing process, water vapours may arise in the stone if
warming up is carried out too quickly; these may not be able to escape via the pores available if heating up is too fast, which
causes the stones to flake (see also Operating Instructions C003/C014 Shell boilers, Chapter Commissioning).
In the case of fuels with a high sulphur level, corrosion of the surface may occur over the years. Minor shrinkage cracks or
flaking will not affect function and are unavoidable.
The front reversing chamber door is provided with thermal insulation mats. These reduce the surface temperatures of the
component, radiation losses and the boiler house temperatures. The mats must be fixed firmly to the door.
The proper function of the thermal insulation can be determined by the temperature of the external surfaces. A reduction in
the insulation effect can be noticed by an increase in the temperature of the surface. If a temperature rise of more than 50C
is determined, replacement of the insulation is urgently required.
Note: All inspection openings closures are provided with special seals. Standard trade seals must not be used
as a substitute under any circumstances. Only Loos International seals may be used.
Page 7 of 7
Shell Boilers
for the producing of hot water
C014
Version 7 (12/08)
Contents
1
Safety .......................................................................................................................................................................... 3
5.1
Dangerous situations.................................................................................................................................................... 4
5.1.1
Exceeding the pressure................................................................................................................................................ 4
5.1.2
Lack of pressure........................................................................................................................................................... 4
5.1.3
Excessively high temperatures..................................................................................................................................... 4
5.1.4
Lack of water ................................................................................................................................................................ 5
5.1.5
Insufficient water flow ................................................................................................................................................... 5
6.1
Construction ................................................................................................................................................................. 5
6.2
Function ....................................................................................................................................................................... 5
6.3
Optional additional equipment...................................................................................................................................... 6
6.3.1
Flue gas heat exchanger.............................................................................................................................................. 6
6.3.2
Systems for maintaining the return flow temperature ................................................................................................... 6
7.1
Rating plate .................................................................................................................................................................. 6
8.1
General notes on transport........................................................................................................................................... 6
8.2
Special transport regulations........................................................................................................................................ 7
8.3
Interim storage ............................................................................................................................................................. 7
Assembly .................................................................................................................................................................... 8
9.1
Place of installation ...................................................................................................................................................... 8
9.2
Assembly staff .............................................................................................................................................................. 8
9.3
Installation .................................................................................................................................................................... 8
9.4
Feed and discharge pipes, valves ................................................................................................................................ 8
10
Electrical Installation ................................................................................................................................................. 9
11
Setting and Adjustment ............................................................................................................................................. 9
12
Controls ...................................................................................................................................................................... 9
13
Start-up ....................................................................................................................................................................... 9
13.1
General ........................................................................................................................................................................ 9
13.2
Start-up preparation ..................................................................................................................................................... 9
13.3
Conditions required on site......................................................................................................................................... 10
13.4
Start-up times when commissioning for the first time ................................................................................................. 10
13.5
General instructions on carrying out the start-up........................................................................................................ 11
Page 1 of 22
Shell Boilers
C014
Version 7 (12/08)
13.6
Trial run and instruction ............................................................................................................................................. 12
14
Operation.................................................................................................................................................................. 12
14.1
Boiler water ................................................................................................................................................................ 12
14.1.1 General ...................................................................................................................................................................... 12

14.1.2 Water samples ........................................................................................................................................................... 13
14.1.3 Blow-down ................................................................................................................................................................. 13
14.2
Recurrent start-ups .................................................................................................................................................... 13
14.3
Normal operation ....................................................................................................................................................... 15
14.4
Keeping warm ............................................................................................................................................................ 15
14.5
Behaviour in the event of operating faults.................................................................................................................. 15
15
Shutting down .......................................................................................................................................................... 15
15.1
Recurrent shutting down ............................................................................................................................................ 15
15.2
Shutting down using the emergency stop switch ....................................................................................................... 16
15.3
Corrosion protection in the event of longer down times ............................................................................................. 16
15.3.1 Water-side preservation through pressure monitoring (independent of time): ........................................................... 16

15.3.2 Wet preservation on the water side for down times of up to approx. 3 months.......................................................... 16
15.3.3 Dry preservation on the water side for down times of more than approx. 3 months: ................................................. 16
15.3.4 Preservation on the flue gas and burner side ............................................................................................................ 17
16
17
17.1
Operating Log ............................................................................................................................................................ 20
17.2
Entering the boiler...................................................................................................................................................... 20
17.3
Repeated, regular inspections and maintenance by the operating and maintenance staff ........................................ 21
17.4
Irregular inspections and maintenance by the operating and maintenance staff ....................................................... 21
17.4.1 Boiler valves and boiler parts ..................................................................................................................................... 21

17.4.2 Boiler cleaning on the burner and heating gas side ................................................................................................... 21
17.4.3 Boiler cleaning on the water side ............................................................................................................................... 21
17.5
Repeated, regular inspections and maintenance by experts or competent persons .................................................. 22
18
Replacement Parts................................................................................................................................................... 22
B006/B009/B011 Recurring inspections for shell boilers (external and internal inspections and water pressure tests)
B007 Checklist, hot water boilers
B010 Check list for heating boilers
G012 Wet and Dry Conservation
Page 2 of 22
Shell Boilers
C014
Version 7 (12/08)
The shell boiler (called the boiler in the following) is used to product warm water or high-pressure hot water.
The marginal parameters defined in the technical data with the order confirmation must be followed. A list of these
parameters is given in Register M. This applies in particular for:
Water parameters
Fuel parameters
Ambient parameters
During the operating phase, load fluctuations beyond the boiler's nominal output should be avoided. Any change in the heat
reduction (= load change speed) must be less than or equal to the speed of change of the incorporated burner output. Care
must be taken to ensure that the switching frequency of the burner on average does not exceed four starts per hour.
During burner operation, a continuous induced circulation of the boiler must be ensured.
Flow monitoring is necessary to monitor this minimum water flow rate. If the flow rate falls below the prescribed minimum
water flow rate, the boiler firing must be switched off.
Furthermore, the temperatures may not fall below the minimum permitted boiler supply and return flow temperatures
(exception: start-up mode)
Information on the necessary minimum water throughput in burner operation and the minimum permitted boiler supply and
return flow temperatures are given in the technical data in the order confirmation.
The requirements for the filling, make-up and circulating water are defined in the Operating Instructions B004 Guideline on
water characteristics. These requirements must be complied with completely at all times.
The system may only be used in a technically perfect state, with full awareness of safety and dangers, by trained specialist
staff who have read and understand the operating instructions in full.
Changes to the boiler, its equipment and controls if these were supplied by Loos International may only be carried out after
written approval has been obtained from Loos International. Any change made independently will invalidate any claims
under the guarantee. In addition, an official operating permit may be cancelled in such cases.
Safety
Page 3 of 22
Shell Boilers
C014
Version 7 (12/08)
5.1
Dangerous situations
During the operation of this system dangerous situations may arise as a result of operation. Damage can only be avoided if
these situations are recognised in good time and if the correct measures are taken immediately. The following list of
dangerous situations makes no claim to be complete, but is based on values from experience that have been gathered
through decades of observing our products. If other installations or system components are present, the measures that apply
for these system components must be coordinated with the manufacturer of these installations or components.
The operating staff must inform their competent superior of dangerous situations immediately.
According to the regional regulations, damage to pressure-bearing walls of the boilers and if provided the Type of
flue gas heat exchanger which, as a result of a danger to the operating staff or third parties, leads to a halt in operation
must be reported to the competent supervisory authority and/or monitoring organisation which is responsible for safety
tests on the boiler system.
The safety equipment affected must be inspected immediately by a competent person and repaired if necessary (if
possible) or replaced. We strongly recommend that such inspections and repair work are carried out by suitably trained
Loos International service engineers or by people who have expressly authorised by Loos International to carry out such
work.
5.1.1
Exceeding the pressure

Danger! Danger if pressure is exceeded. Exceeding the pressure may lead to the destruction of the boiler. Parts
that are flung out and the leakage of the hot medium (steam, hot water) can cause fatal injuries to persons in the
vicinity of the boiler.
If the pressure is exceeded, the pressure limiter must be triggered, causing the firing to be switched off and locked. If the
pressure limiter fails, the pressure safeguard valve is triggered and releases the excess pressure. If the pressure safeguard
valve does not respond or if the pressure in the boiler rises above the red line marking on the pressure indicator in spite of
the blow-off from the pressure safeguard valve, the boiler heating must be switched off immediately. If necessary, the
emergency stop switch must be used.
The boiler may only be started up again when the causes for the failure of the pressure limiter and/or the failure of the
pressure safeguard valve have been properly removed and a competent person allows the boiler to be fired again after a
corresponding inspection. Loos International recommends that this inspection is carried out by suitably trained Loos
International service engineers or by people who have expressly authorised by Loos International to carry out such work.
5.1.2
Lack of pressure
Danger! Danger from lack of pressure. If there is insufficient pressure, water may vaporise in the boiler and get
into the pipes. In extreme cases, this may ultimately cause damage to the system, causing potentially fatal
injuries.
If there is a lack of pressure, the pressure limiter must be triggered, causing the firing to be switched off and locked. If the
pressure limiter fails, the boiler heating should be switched off immediately. If necessary, switch off using the emergency
stop.
The boiler may only be started up again when the causes of the pressure limiter's failure have been expertly repaired and a
competent person allows the boiler to be fired again after a suitable inspection. Loos International recommends that this
inspection is carried out by suitably trained Loos International service engineers or by persons who have been expressly
authorised by Loos International to carry out this work.
5.1.3
Excessively high temperatures

Danger! Excessively high temperatures can be dangerous. They can cause serious damage to the boiler, or
even completely destroy the boiler. In extreme cases, this may ultimately lead to very serious damage to the
system, causing potentially fatal injuries.
If the temperature becomes excessively high, the temperature limiter must be triggered, causing the firing to be switched off
and locked. If the pressure limiter fails or if the temperature in the boiler rises above the permitted temperature, the boiler
heating should switched off immediately. If necessary, switch off using the emergency stop.
Page 4 of 22
Shell Boilers
C014
Version 7 (12/08)
The boiler may only be started up again when the causes of the temperature limiter's failure have been expertly repaired and
a competent person allows the boiler to be fired again after a suitable inspection. Loos International recommends that this
inspection is carried out by suitably trained Loos International service engineers or by persons who have been expressly
authorised by Loos International to carry out this work.
5.1.4
Lack of water
Danger! There is a danger from lack of water. It can cause serious damage to the boiler, or even completely
destroy the boiler. In extreme cases, it may cause extremely serious damage to the plant, and people may suffer
fatal injuries.
If there is a shortage of water, the level limiting device should be triggered, causing the firing to be switched off and locked. If
the level limiter fails, the boiler heating must be switched off immediately. If necessary, the emergency stop switch must be
used.
The boiler may only be started up again when the causes for the failure of the level limiter have been properly removed and
a competent person allows the boiler to be fired again after a corresponding inspection. Loos International recommends that
this inspection is carried out by suitably trained Loos International service engineers or by people who have expressly
authorised by Loos International to carry out such work.
If lack of water has caused damaged to the boiler (e.g. deformation of the flame tube or similar), the boiler must be shut
down immediately. The boiler may only be started up again when the damage that has occurred has been properly repaired
and a competent person allows the boiler to be fired again after a corresponding inspection. Loos International recommends
that this inspection is carried out by suitably trained Loos International service engineers, unless a monitoring organisation
has been consulted.
5.1.5
Insufficient water flow

Danger! There is a danger if insufficient water flows through the boiler. If this happens, it may cause
overheating, temperature lamination in the boiler and incorrect switching of temperature regulators and limiters.
In extreme cases, this may ultimately lead to very serious damage to the system, causing potentially fatal
injuries.
If the water flow falls below the minimum, the flow monitoring system must respond and switch off the firing. If it is not
switched off automatically in the event of an insufficient water flow, the boiler heating must be switched off immediately. If
necessary, switch off using the emergency stop.
The boiler may only be started up again when sufficient water is flowing through the boiler again.
6
6.1

Construction
The boiler pressure hull is a horizontal cylinder, closed off with boiler ends on both sides and insulated all round. The entire
boiler is filled with water during operation. The flame tube and the smoke tubes run lengthways through the cylindrical body.
The flame is blown by the burner into the flame tube from the front end of the boiler. It burns out in the flame tube. The hot
flue gases created when the flame burns out are forwarded into lots of small smoke tubes. The gases are passed by these
pipes through the boiler to the rear end of the boiler.
6.2
Function
The flame and the resultant flue gases flow through the flame tube and the smoke tubes. The boiler pressure hull itself is
filled with water, and the water flows into the boiler via the return flow connection and back into the network via the forward
flow connection. The water cools the outside of the flame and smoke tubes lying lengthways in the boiler pressure hull.
During this "cooling process", the boiler water warms up, so that warm or high-pressure hot water can be provided to the
consumer unit. A sufficient flow through the boiler is maintained by a circulating pump.
To ensure that the warmed or heated water does not evaporate in the boiler, a pressure-monitoring device is required to
maintain the boiler operating pressure.
Page 5 of 22
Shell Boilers
C014
Version 7 (12/08)
The burner capacity and thus the required boiler output are regulated via the set mean supply flow temperature. If the
temperature of the boiler water at the boiler outlet falls below the set value, the burner is switched on or the burner capacity
increased. If the boiler output temperature reaches the set maximum value, the burner is switched off, since no heat is
required. If this regulation mechanism fails, a temperature limiter switches off and locks the burner.
6.3
Optional additional equipment
6.3.1
Flue gas heat exchanger
In the flue gas heat exchanger, warmth is recovered from the boiler flue gases which would otherwise be lost through the
chimney without being used. The energy recovered in this way makes the boiler more efficient and reduces fuel
consumption whilst improving flue gas emission levels.
F012 Flue gas heat exchanger
6.3.2
Systems for maintaining the return flow temperature
In order to avoid impermissibly low boiler return flow temperatures or impermissibly high temperature differences between
the boiler return flow and forward flow, systems to maintain the return flow temperature are necessary.
Please read the Operating Instructions.
E016 Maintaining the return flow temperature
7.1
Rating plate
The parameters specified on the rating plate must not be exceeded. The rating plate is either located on the top right of the
front end or at the boiler shell in 3 oclock position at a distance of approx. 300 mm from the front end.
8
8.1

General notes on transport
When transporting the systems, suitable protective measures should be taken, which will depend on the type of transport
chosen. If necessary, Loos International will advise you on the choice of suitable protective measures. In any case, transport
must be carried out with due caution. Unnecessary loads on the components should be avoided. If required, and for a
charge, the delivery can be packed for transport by Loos International and delivered with the appropriate protection.
Caution! Incorrect lifting can seriously damage the equipment. Lifting equipment and stop devices should only
be fixed to the attachment points described below. Only use lifting equipment and stop devices that are suitable
for the weight loads which will occur.
If a crane is used, the boiler may only be lifted at the marked lifting rings (see figure) on the cylindrical part of the boiler;
it is essential that all the lifting rings affixed to the cylindrical part must be used.
Page 6 of 22
Shell Boilers
C014
Version 7 (12/08)
Important! The angle of inclination of the lifting accessories must be 90 .
If the location of the boiler has to be changed, the boiler may only be lifted at the lifting jacks, which are attached to the
boiler feet. Small boilers (transport weight < 4 t) may be lifted by suitable means (e.g. conveyor vehicles, lifting
equipment) at the points where the boiler feet are fixed to the base frame.
Important! For floor-level boiler transport, means of transport under the base frame may exclusively be placed
below the boiler feet.
The use of tank steel rollers below the base frame is inadmissible for floor-level transport. Danger of base
frame deflexion!
If the location only needs to be changed approximately in the direction of the boiler's longitudinal axis, only the bored
holes at the front and back of the base frame may be used.
Stop points on buildings or parts of buildings for pulling the boiler must be suitable for the forces arising and may only
be used after they have been approved beforehand by the manufacturer of the system.
If the boiler, because of the situation on site, cannot be transported as described above, it is essential that Loos
International is consulted.
8.2
Special transport regulations
The following instructions must be followed under all circumstances:
Avoid wet or damp situations
When transporting insulated systems or system components on open vehicles, suitable packaging should be provided
to protect the equipment from the effects of water and weather.
Avoid vibrations as far as possible
Do not under any circumstances expose the systems or system components to temperatures below -20 C (danger of
embrittlement fractures).
For transport by sea, use suitable packaging (overseas containers). If the system is packed in a wooden crate, it may
not under any circumstances be transported on deck.
Make sure that sufficient suitable corrosion protection is provided whatever form of transport is chosen.
Transport vehicles must be fitted with pneumatic or hydraulic suspension to prevent vibration cracking.
8.3
Interim storage
If the system has to be stored, the following instructions must be followed under all circumstances:
Store in a dry (humidity < 60%), dust-free place.
Temperature change in the store < 10 K/h.
Never expose the system to temperatures below - 50C. Restrictivy applies: Items of equipment, sensors and the
control cabinet should never be exposed to temperatures below - 20C.
Page 7 of 22
Shell Boilers
C014
Version 7 (12/08)
9
9.1
If the system is stored insulated and covered with the protective wrapping provided for transport, the protective
wrapping should be cut open at the base for the full length to prevent condensation and thus oxidation on the insulation
surface.
Assembly
Place of installation
the system may only be erected in a room that meets the local regulations for the erection of boiler systems. In any case,
care should be taken to ensure that the floor at the place of installation is absolutely flat (evenness tolerance in according to
DIN 18202: 10 mm) and sufficiently strong. The room must be frost-free and large enough for access to the system to be
ensured in accordance with the local regulations.
The place where system is installed must be designed in terms of building physics in such a way that vibrations caused by
the process cannot cause any damage to buildings or neighbouring systems.
An adequate ventilation for air intake and removal must be provided.
9.2
Assembly staff
Transport to the site, assembly and later disassembly of the system should exclusively be carried out by appropriately
trained and qualified personnel with the necessary technical know-how and authorisation for this task from the installer of the
entire system.
9.3
Installation
When the plant is installed, the regional regulations must be complied with (e.g. structural requirements, open spaces for
operation and maintenance, emergency exit routes, etc.).
The boiler does not need to be anchored to the place of installation.
Note: It should be noted that with particular types, the rear boiler support (seen from the burner side) is made as
a fixed point on the longitudinal support. The front boiler support is made as a loose bearing, i.e. the boiler
expands forwards as it heats up.
If the place of installation and the boiler have to be separated due to structure-borne sound, sound insulation strips must be
affixed before the boiler is erected.
If the boiler is installed on steel supports or other materials that are good heat conductors, insulation must be provided
between the boiler longitudinal supports and the installation surface, e.g. using sound insulation strips.
Note: If a boiler with waste gas connection socket arranged to the top has the chimney mounted directly on the
waste gas connection socket respectively the incorporated flue gas heat exchanger, then it must be considered
that the load and the horizontal forces (e.g. caused by wind load) cannot affect the boiler. Therefore, a separate
support for the chimney is required. In addition, we recommend a decoupled arrangement for the chimney (e.g.
with expansion joint) from the boiler- flue gas heat exchanger system in order to interrupt the structure-borne
sound.
Furthermore, it must be prevented by a cover on the chimney or a certain device inside the chimney or the waste
gas line that rain enters into the boiler. Depending on the operating conditions, the moisture might lead to
corrosions in the boiler and the flue gas heat exchanger.
9.4
Feed and discharge pipes, valves
All feed and discharge pipes must be laid in accordance with the regional regulations and in line with the accepted technical
rules.
For further information, please read the technical information sheet TI024 Requirements for Boiler Installation Rooms (notes
for the installation of boilers and boiler house components).
Page 8 of 22
Shell Boilers
C014
Version 7 (12/08)
The electrical installation work may only be carried out by trained, qualified electricians (e.g. according to the
guidelines laid down by the VDE or comparable institutions at the place where the system is to be installed). It
must be done in accordance with the recognised electrotechnical rules and the local regulations and must be
suitable for damp rooms.
The system is designed for a power supply with a nominal voltage and nominal frequency according to the technical data in
the order confirmation.
Electronic equipment that forms a part of this system may only be installed and connected to the power network or the
control cabinet by trained, sufficiently qualified electricians. The automatic control or other electronic component may not be
opened during installation or at any other time by the user or by other people. They do not contain any parts that can be
repaired by the user. Repairs may only be carried out by the manufacturer of these components. If these components are
opened by unauthorised persons, this shall invalidate any guarantee claim.
Important! The installation of the control panel is to be carried out in such a way that no vibrations or shaking
from the boiler or other devices can be transmitted to the control panel. It shall be erected in areas that protect
the control panel against excess thermal radiation and which allow access safely in dangerous situations.

No particular setting and adjustment work is required during installation.
12 Controls
Note: If the system's controls are not supplied by Loos International, the system must be operated according to
the operating instructions for the controls that are actually used.
Notes on the controls are given in the circuit diagram and the operating instructions for the controls and process technology
in Registers G and/or H.
13 Start-up
13.1 General
For the start-up of the boiler, all the other components of the boiler house (e.g. fuel supply devices, water treatment systems
flue gas systems etc.) must be provided in working order by their suppliers. Equipment that has an influence on the function
of the components supplied by Loos International must be coordinated carefully. Operation without faults and without
damage is only possible if all part components are working perfectly.
All people who are entrusted to carry out the maintenance and supervision of the boiler must be present during the start-up
works, and the immediate superiors of these persons should be present for at least part of the time.
13.2 Start-up preparation

The following points must be carried out before start-up:
The inside of the boiler must be subjected to visual examination before being filled with water for the first time and if
necessary (foreign matter in the inside of the boiler due to transport, storage or assembly) must be rinsed through.
Before start-up or before attachment of the burner, the boiler must be visually examined on the flue gas side (foreign
matter in the inside of the boiler due to transport, storage or assembly).
Page 9 of 22
Shell Boilers
C014
Version 7 (12/08)
Closures must be checked before filling to ensure that they are seated centrally, that the clamps are correctly positioned
and for pressure. (See also Operating Instructions K022 Inspection Openings, steam and water side).
All seals (gaskets) must be tested for tightness.
The movement of all shut-off valves must be tested; their seals and packings, if provided, must be tightened if
necessary and tested in accordance with their operating instructions.
The water reservoirs of sensors must be filled with distilled water.
Transport securing devices and protective wrappings, if provided, must be removed.

Important! It is mandatory to open the shut-off valve at the manostat tube. For safeguarding the open state, it is
necessary to lock the hand wheel by screwing in the greasing nipple up to the limit stop (also see Operating
Instructions K007 Shut-off Valve).
13.3 Conditions required on site

For the beginning of the start-up work, the owner of the plant or his agent must meet the following conditions:
The room in which the boiler is erected must be in a tidy condition. Building works and activities that cause dust or
moisture must be completed.
Openings for air intakes and outlets must be provided in sufficient size and must be operable.
The lighting of the room, especially the display devices at the boiler, must be sufficient to allow them to be read off
perfectly.
Emergency exit routes must be kept clear, doors must open outwards (safety doors) and may not be locked.
Access by unauthorised persons must be forbidden by a sign erected by the owner.
In the boiler room, a fire extinguisher suitable for the extinguishing of oil fires in the case of oil-fired boilers must be
provided at an easily accessible point.
The chimney and flue gas outlet routes must be leak-tight. In the case of oil and gas fired boilers and firing systems of a
particular design, devices must be provided which only allow the firing to operate when they are open (limit switches).
Masonry chimneys and flue gas ducts must be sufficiently dried. In cases of doubt, the approval of the manufacturing
company must be obtained.
Brick linings in the boiler must be dried. Possibly existing supporting material for brick linings must be removed before
commissioning.
All necessary operating equipment must be provided with the technical data given in the order confirmation.
The relevant electrical regulations must be noted, especially the protective measures prescribed locally. Emergency
switches to the emergency exit doors must be connected so that they are functioning properly.
Containers and pipelines must be thoroughly cleaned before the commencement of start-up works.
For the start-up and trial run, the owner must allow performance outputs through all the load stages of the boiler in
question or the plant as a whole so that the firing and the control and safety equipment can be set in such a way that
later faults are avoided. In particular, a sufficiently long acceptance process in accordance with the maximum
continuous load is essential for optimum setting.
Depending on the type of system, other points may arise as preconditions. The owner has been made aware of these
preconditions in a suitable form in good time. If these preconditions are not fulfilled or are only partly fulfilled, the start-up
may be delayed or it may be impossible to carry it out in full. Any delays and risks resulting from this shall be the
responsibility of the client for these works.
13.4 Start-up times when commissioning for the first time

The boiler lining contains an amount of residual water due to the manufacturing process. The water is evaporated the first
time the boiler is heated up. The water vapour that is created must escape during the entire heating up process. This may
cause small shrinkage cracks. Minor cracks or spalling will not have any adverse effect on function and are unavoidable.
Page 10 of 22
Shell Boilers
C014
Version 7 (12/08)
Note: Because of the cooler ambient air in the boiler house, there will be, in the area of the burner plate, some
condensation of the escaping water vapour from the wall lining (the formation of condensation may continue for
up to a week). This is shown by droplets of water on the burner plate seal.
Caution! If heating up is carried out too quickly, the water vapour created cannot escape via the pores in the
brick lining and spalling of the stones may occur, which may even lead to a total destruction of the brick lining. In
order to prevent the brick lining from being destroyed, it is essential that the specifications for heating times are
followed.
The necessary removal of vapour from the brick lining is guaranteed if the requirements of the following table are met:
Operation of burner at low load

(maximum 50% load)
Operation of burner at full load
Heating up time
10 min.
Downtime
60 min.
Heating up time
20 min.
Downtime
60 min.
Heating up time
30 min.
Downtime
30 min.
Heating up time
30 min.
Downtime
30 min.
Heating up time
60 min.
Downtime
30 min.
Total time
6 hours
Caution! When commissioning for the first time, the complete heating up procedure must be carried out. Under
no circumstances should a brief start-up be tried and then stopped again.
13.5 General instructions on carrying out the start-up

The initial start-up of components supplied by Loos International may only be carried out by employees of the
company Loos International or by people whom Loos International has expressly authorised to carry out such
work.
The following notes on carrying out the initial start-up apply for the boilers supplied by Loos International if the equipment
and control of the boiler were not provided by Loos International:
Warning! Pumps may be filled with anti-freeze preservatives. Empty the pumps via the drainage plugs, rinse
through once and fill with water.
Before pumps are started up, the preconditions given in their operating instructions must have been met.
Fill boiler completely with treated water. The water temperature should be the same as the boiler wall temperature. With
differences of over 50 K, the filling time in continuous filling may not be less than 2 hours (danger of brittle fracture).
Check fuel pipes for leak-tightness.
Rinse suction lines in oil firing systems the part between the filter and the pump with pure heating oil.
Before the start-up of burners, the preconditions given for them in the special operating conditions must be fulfilled, and
in particular the flow of water through the boiler must be ensured by means of circulating pumps. The burner capacity
must be matched to the heat output. The quantity of fuel necessary for this must be defined, unless it is clear from the
order. In the case of oil burners, the nozzles must be checked. Meter readings of oil or gas meters should be noted.
Measurement and control devices must be set according to the individual operating instructions of these components.
Page 11 of 22
Shell Boilers
C014
Version 7 (12/08)
Pressure-limiters must react before the pressure safeguard valve. The trigger points of controllers and limiters must be
sufficiently distant from each other and from the limiters.
The trigger points of temperature controllers and limiter must be coordinated to each other.
Tighten up flange connections and screw connections frequently during the heating up process.
Tighten up connections at the boiler's inspection openings and reversing chambers.

Important! Inspection openings are located at the points under the insulation marked by the following sign. For
retightening the connections, carefully remove the insulating strip and the insulation mat below and attach them
again thoroughly after retightening.
Note: During start-up or the subsequent trial operation, if required under regional regulations, the competent
monitoring organisation must carry out the necessary inspections of the boiler system so that the boiler system
can continue seamlessly to be operated as soon as the start-up is completed. The owner or his representative
must ensure that the organisation is notified and the dates agreed in good time.
13.6 Trial run and instruction

The duration of the trial run depends on the times and conditions agreed in the order confirmation.
If no arrangements were made for a trial run in the order confirmation, instruction will be provided for the operating staff
during or immediately after the start-up.
The completion of the trial run (or, if no trial run is carried out, the completion of the start-up) and the associated training of
the operating staff must be confirmed in writing by the owner or his representative, generally by signing the assembly
certificate or corresponding document provided by our service engineer.
Note: In the first few days after completion of the start-up, all filters should be cleaned several times. If the
system continues to be operated, particular attention should be paid to the quality of the boiler water. It is often
found that foreign matter enters the boiler through the water circulation, making drainage and refilling necessary
after just a short time, sometimes only a few days.
14 Operation
14.1 Boiler water

14.1.1 General
The operation of modern, energy-saving boilers assumed that the water will have been pretreated accordingly to avoid heatinsulating deposits especially limescale and corrosion. The values listed in the operating instructions B004 Guideline on
water characteristics must therefore be strictly complied with when designing the water treatment and during boiler
operation. If raw water is not taken from the municipal water network, but is taken, for example, from rivers or the company's
own wells, it is recommended that particularly experienced specialist companies are instructed to supply, set up and
maintain the water treatment plant.
Condensate containing oil or grease may not enter the boiler under any circumstances!
Page 12 of 22
Shell Boilers
C014
Version 7 (12/08)
Warning! Severe damage to the system can be caused by insufficiently treated water or unsuitable dosing
agents. Coatings should not be assumed to be harmless. The thickness of the coatings is not an indication of its
heat-blocking effect!
The function of the water treatment, the raw water characteristics, and the associated pipelines and valves must be checked
regularly. The system must be examined regularly for possible entries of foreign matter into the water cycle. Corresponding
entries must be made in the operating log (see Chapter 17.1). The chemical removal of boiler deposits or boiler scale may
only be assigned to experienced specialist firms.
14.1.2 Water samples

The boiler circulating water must be inspected at regular intervals (see Operating Instructions B007/B010 Checklist, hot
water boilers) and the results of the analyses are to be recorded in the operating logbook (see chapter 17.1.
It is essential that a water sample cooler be used to remove the boiler water sample. We recommend the use of the water
sample cooler made by Loos International. If water samples are analysed that are taken incorrectly or via unsuitable water
sample coolers, analytical errors are bound to occur. All water samples may only be taken and analysed in accordance with
the operating instructions B004 Guideline on water characteristics for hot water boilers and E004 Water sample coolers.
Other methods and procedures are not permitted.
Warning! Danger of serious scalding. Removing water samples without suitable water coolers may cause
severe scalding.
14.1.3 Blow-down
Every boiler must be blown down to prevent sludge deposits from forming. These sludge deposits are caused by correcting
chemicals that have loosened or of which a surplus has been added, residues from the attached system, or corrosion
residues or other foreign matter which have entered the boiler via the water.
Warning! Danger of boiler damage through overheating. This is caused by excess sludge deposits.
Generally, corresponding sludge traps are installed in the hot water system, and so a manually operated blow-down device
is therefore sufficiently. This should be operated carefully once a month.
Warning! There is a danger that the system could switch off if the pressure falls too much if automatic quick
shut-off blow-down valves are installed. The installation of automatic quick shut-off blow-down valves is not
permitted.
Note: We would like to point out expressly that leaking waste water or flue gas condensate should not under any
circumstances be disposed of without previously checking the waste water values. If necessary, the waste water
should be treated in such a way (neutralising, cooling, etc.) that it meets the local regulations on the disposal of
waste waters into the sewage system.
14.2 Recurrent start-ups

If system parts are mentioned in the following that are not a part of our delivery, this is done on a non-binding basis. The
operating instructions of the suppliers in question are decisive. The following sequence must be followed precisely:
The conditions given in section "Conditions required on site" must be met.
All necessary system components are ready for operation.
The system is under operating pressure.
If Flue gas heat exchangers are provided, they must comply with the valid operating instructions.
Page 13 of 22
Shell Boilers
C014
Version 7 (12/08)
Open air intake and outlet opening, if not automated, and secure against closure.
Open flue gas flaps, if not automated, and secure against closure.
Make sure fuel supply is ready for operation, open shut-off valves.
Note: The following further description assumes that the boiler is fitted either with a boiler circuit pump with a
three-way control valve for return flow temperature control or alternatively with a booster pump.
Open supply flow shut-off device and return flow shut-off device. The network pumps are not yet operating.
Switch on main switch at control cabinet and deal with any fault messages. Unlock boiler and burner control.
In the model "Boiler circuit pump with three-way control valve for return flow temperature control " , the three-way control
valve is to be set by hand to boiler circuit and the return flow temperature control set to manual mode.
Switch on boiler control at control cabinet if a separate switching function is provided.
If necessary, clear any existing fault alarms. Unlock boiler and burner control.
If a return flow temperature monitor is installed has been triggered, it should be deblocked. The task of the return flow
temperature monitor is to switch the system off if the temperature falls below the minimum boiler return flow
temperature. (Basic setting approx. 2 K below the min. permitted return flow temperature). When starting up the boiler,
the return flow temperature monitor should generally be switched in such a way that, on switching on or deblocking, it
remains ineffective until the set temperature a the return flow temperature monitor has been exceeded for the first time.
From this point in time, the monitor is active and reacts as soon as the temperature falls below the set temperature.
Switch output control to manual at control cabinet.
Switch burner control on at control cabinet.

Important! The boiler circuit pump or booster pump must be operating by the time the burner is switched on at
the latest.
Start up burner according to separate operating instructions. Monitor start-up of oil and gas firing to determine any
irregularities and repair them, e.g. hard ignition, uneven burning.
The boiler must be heated up at minimum load to almost supply flow temperature. A sufficient quantity of water must be
passed through the boiler all the time by means of the boiler circuit pump or booster pump.
Once the set average supply flow temperature has been reached, switch performance regulation to automatic mode.
Set control device for ensuring the return flow temperature (control valve e.g. three-way control valve) to automatic, if it
is automated and not already in this position.
Switch in network pumps. Make sure that the temperature does not fall below the minimum boiler return flow
temperature and the maximum temperature difference between the boiler supply and return flow is not exceeded. If
necessary, the volume flow of the network pump(s) should be reduced.
The daily inspections and other maintenance work should only be carried out once the boiler has been fully started up
and is in automatic mode (see chapter on "Care and Maintenance").
If the boiler is not fitted with a boiler circuit pump or booster pump, it must be ensured, depending on the connected hot
water network, that firstly the boiler is heated up to supply flow temperature with a steady through-flow and that the
connected consumer units are only switched on gradually after this. Care should be taken to ensure that the temperature
does not fall below the minimum boiler return flow temperature and that the maximum temperature difference between the
boiler supply and return flow is not exceeded. If necessary, the volume flow of the network pump(s) should be reduced.
Important! As long as the boiler is operated below the minimum permitted boiler supply and return flow
temperatures (information on this is given in the technical data in the order confirmation), the temperature is
below the water dew point in gas operation in particular and flue gas condensate will leak out of the flow gas
hood. This flue gas condensate is highly corrosive and must be removed from the boiler immediately. Closing the
flue gas condensate drainage at the boiler is not permitted.
Page 14 of 22
Shell Boilers
C014
Version 7 (12/08)
Note: We would expressly like to point out that leaking waste water must not be disposed of under any
circumstances without the waste water values being checked first. If necessary, the waste should be treated in
such a way (neutralising, cooling, etc.) that it meets the local regulations on the discharge of waste waters.
14.3 Normal operation

Important! Care should also be taken during normal operation that the water through-flow does not fall below
the minimum rate at any time during burner operation. In addition, make sure that the temperatures do not fall
below the permitted minimum boiler supply and return flow temperatures.
14.4 Keeping warm

As an option with multi-boiler systems, there is a facility for keeping warm via network water. For this the firing and if
necessary the boiler circuit pump or booster pump assigned to the boiler are switched off. The return flow shut-off device is
closed, and the supply flow shut-off device is open. Using an additional heat maintenance pump, which is connected on the
suction side at the boiler outlet, network supply flow water is pumped through the boiler to be kept warm into the network
return flow.
Important! Heat maintenance only via the network circulating pump, boiler circuit pump or booster pump is not
sufficient. Because the firing is switched off in heat maintenance mode, there is no boost in the boiler and there
will be a short-circuit flow between the boiler supply and return flow. An even temperature in the boiler is no
longer guaranteed and the base of the boiler cools down. When the boiler, which is assumed to be warm, is
started up again, addition stresses occur which can lead to damage to the boiler.
14.5 Behaviour in the event of operating faults

In the event of a fault that is relevant to safety, the system switches off automatically if the control was supplied and
maintained by Loos International. If provided, an acoustic warning tone will be heard. In the case of boilers with a fault
display device, the fault will also be displayed and saved.
Determine the cause of the fault using the information provided in the chapter Measures in the event of unusual operations
and operating faults and remove it. You should also note the operating instructions and if necessary the visual displays of
the individual additional devices. If the cause of the fault remains unclear or the fault cannot be repaired with the means
available, the nearest Loos Service office should be notified. You will find the Loos Service numbers on the outside of your
boiler's control cabinet.
Important! The system may only be started up again once the cause of the fault has been determined and
repaired.
15 Shutting down
15.1 Recurrent shutting down
If system parts are mentioned in the following that are not a part of our delivery, this is done on a non-binding basis. The
operating instructions of the suppliers in question are decisive. The following sequence must be followed precisely:
Switch burner to minimum load position and then switch off.
Wait while circulating pump (boiler circuit pump or booster pump if provided) runs down.
Switch off pump and close return flow shut-off valve.
The supply flow shut-off valve stays open (unless the boiler is to be completely removed from the network for inspection
works).
If flue gas heat exchangers are provided, they must comply with the valid operating instructions.
Switch off burner and boiler control at control cabinet.
Page 15 of 22
Shell Boilers
C014
Version 7 (12/08)
Close flue gas flaps, if not automated.
Close air intake and outlet opening, if not automated.
Switch off fuel supply, close fuel shut-off taps.
Switch off main switch at control cabinet.
Shut down other system components according to their operating instructions.
15.2 Shutting down using the emergency stop switch

In potentially dangerous situations, the firing can be switched off and locked by operating the emergency stop switch or the
main switch in the control cabinet.
Warning! Danger of boiler damage. Before the boiler system can be started up again after an emergency shutdown, the cause for the emergency shut-down must be repaired and the system inspected. Only when all causes
have been safely repaired may the system be started up again.
After unlocking of the emergency stop switch, switching back on should be carried out as described in section 14.2
"Recurrent/daily start-up".
15.3 Corrosion protection in the event of longer down times

Any oxygen in the air which enters has a corrosive effect in the cooled, unpressurised boiler. For this reason, suitable
precautionary steps must be taken. If boilers are idle for longer than 3 days, corresponding protective measures must be
taken Loos International recommends the following:
15.3.1 Water-side preservation through pressure monitoring (independent of time):

If one or more boilers in a boiler system are switched off and if it is ensured that one boiler, or at least the pressuremonitoring unit, remains in operation, no further water-side preservation measures are necessary. Care should merely be
taken to ensure that the boiler stays connected with the network through the opened supply flow shut-off device
(alternatively, the return flow shut-off device can also be opened; the important thing is that both shut-offs are not open in
order to prevent heat losses through undesired circulation), and thus that the network pressure is maintained. This ensures
that no oxygen can get into the boiler due to an overpressure situation.
15.3.2 Wet preservation on the water side for down times of up to approx. 3 months
The boiler is filled completely with water, an excess of oxygen binder added and the boiler water content rotated at defined
intervals.
You will find instructions on wet preservation from Operating Instructions G012 Wet and Dry Preservation.
Carrying out the conservation
In order to ensure an even mixing of the dosing agent (for concentration in boiler water, see Operating Instructions G012
Wet and Dry Preservation) with the boiler water, a regular circulation is essential. For this, a circulating pump should be
installed, which is incorporated on the suction side with a T-piece at the outlet connection after the drain shut-off valve and
on the pressure side into the return flow between the boiler and the return flow shut-off device. Dosing agent can be added
via the dosing station on the pressure side of the circulating pump.
All valves at the boiler should then be shut tightly to prevent the penetration of oxygen from the air during the down time. To
ensure a good mixing through of the preservation solution, the water must be circulated five times at least every three days
using the circulating pump.
G012 Wet and Dry Conservation
15.3.3 Dry preservation on the water side for down times of more than approx. 3 months:
The system is completely emptied, filled with special drying agents and then sealed again. Rendering the system fully
operational again takes considerably longer than with wet preservation (approx. 1-2 days) and it is recommended that the
Loos International service engineer is consulted for this.
Page 16 of 22
Shell Boilers
C014
Version 7 (12/08)
Precise instructions for dry preservation are given in Operating Instructions G012 Wet and Dry Preservation.
15.3.4 Preservation on the flue gas and burner side

To preserve the flue gas side in the case of long down times, sufficient through ventilation must primarily be ensured. For
this, swivel the burners out and open any valves on the flue gas side completely. This generally creates a sufficient through
draught through the pull from the chimney.
Any deposits on the flue gas side in which moisture could be bound must be removed before preservation.
If the system is one that is driven by pressure on the flue gas side, or if it is a multi-boiler system in which several boilers are
connected to one chimney, a separate system-specific preservation on the flue gas and burner side must be defined for
these systems, in agreement with Loos International.
In more difficult conditions, such as:
erection in the immediate vicinity of the sea,
if the air is particularly damp,
in the presence of corrosive media,
dry preservation on the flue gas side is recommended. In this case, please proceed analogously as described in Operating
Instructions G012 Wet and Dry Preservation, Section 6.3 "Dry Preservation" and 6.4 "Restarting after preservation".

repair:
Observation/fault:
Min./Max. pressure limiter/pressure safeguard valve triggered
Cause
Repair
Pressure limiter set incorrectly, moved or faulty
Check pressure limiter
Mean network gauge pressure PM too close to

trigger pressure of the pressure limiter
Adjust mean network gauge pressure PM
Supply and return flow shut-off valve closed during

heating
Open shut-off valves and ensure minimum throughflow
Observation/fault:
By whom?
Temperature limiter triggered
Cause
Repair
Temperature limiter set wrongly, incorrectly

adjusted or faulty
Check temperature limiter
Mean forward flow temperature TM too close to

trigger temperature of temperature limiter
Set mean forward flow temperature TM lower
By whom?
Page 17 of 22
Shell Boilers
C014
Version 7 (12/08)
Observation/Fault:
Boiler safety chain triggered (boiler fault)
Cause
Repair
Triggering of one or more boiler safety functions or

limiters
After repairing the fault, release safety fuse chain

using release key on boiler control cabinet
Power supply interrupted
Provide power supply to control cabinet (infeed)

acc. to current regulations
Main switch in OFF position
Switch main switch on
Observation/Fault:
Burner fault
Cause
Repair
Various burner faults
See display for firing manager or burner operating

instructions
Observation/fault:
By whom?
Burner does not start
Cause
Repair
Burner switch in OFF position
Switch burner switch on
Burner faulty
Repair burner fault and unlock with unlocking device

at burner or at boiler control cabinet
Boiler fault
Repair boiler fault and unlock with unlock key in

boiler control cabinet or directly at limiter
Flue gas flap not open
Open flue gas flap
Automated air intake flap not open
Check function of air intake flap
Boiler circulating pump not working
Check function of pump
Observation/fault:
By whom?
By whom?
Burner switches on an off frequently
Cause
Repair
Temperature difference between Burner On and

Burner Off not enough
Increase temperature difference
By whom?
Page 18 of 22
Shell Boilers
C014
Version 7 (12/08)
Observation/fault:
Burner only running on low or medium load
Cause
Repair
Performance regulation only released for low or

medium load
Release performance regulation in controller menu
Observation/fault:
Continuous fluctuation of performance regulation
Cause
Repair
Switching points set incorrectly
Check control parameters and switching points
Temperature transmitter faulty
Replace temperature transmitter
Observation/fault:
By whom?
With gas operation, the safety shutoff valve is triggered
Cause
Repair
In a load level, burner switches to down > low load
Sudden change in heat emission in the network
Delay reduction in emission of heat
Observation/Fault:
By whom?
By whom?
No control voltage/control fusing tripped
Cause
Repair
One or more control circuit fuses triggered
Check control circuit fuses and electr. system acc.

to current regulations
No power supply to control cabinet

By whom?
Page 19 of 22
Shell Boilers
C014
Version 7 (12/08)
Observation/fault:
Return flow temperature monitoring triggered
Cause
Repair
Return flow temperature too low
Reduce heat removal from network, reset return

flow temperature monitoring
Control device for maintaining return flow

temperature is not working
Check function of control device

Reset return flow temperature monitoring
By whom?
Note: If boiler damage occurs, ore details are given in the operating instructions B006/B009/B011 "Regular
inspections," in the chapter "Measures in the event of unusual observations or operating faults." Further
information is given in the operating instructions for the components in question.

17.1 Operating Log
An operating log is to be kept of inspections and maintenance work which must be signed off by the operating staff. The
maintenance work carried out by the competent person must also be entered in this operating log. The forms contained in
Register L (Forms) of these operating instructions should be used for this. Operating logs may be obtained from Loos
International.
The superior of the operating staff must ensure at least once a month that the boiler system is being properly operated and
maintained, and must note this on the back of the sheet in the operating log by signing and giving the date.
Note: Entries must be made in the operating logs at the required intervals. The careful execution of inspections,
proper maintenance and full entries in the operating logs are a precondition for any guarantee claims.
17.2 Entering the boiler

Before the plant is entered, all pipe connections to the boilers still in operation must be safely and visibly disconnected (blind
flange, removal of pipe sections, shut-offs with interim ventilation).
Warning! Danger of personal injury. Merely closing the shut-off valves is not sufficient!
Suitable warning signs must be affixed, which may only be removed by the superiors of the operating and maintenance staff.
Before the boiler is entered, it must have been cooled down sufficiently (< 40C) and sufficient ventilation must be provided.
There may be no dangerous gases, e.g. nitrogen in the boiler any more.
Movement in the boiler must be monitored constantly from outside the boiler by an adult, reliable, trained person. When the
work has been finished, before the boiler is resealed, the superior of the operating and maintenance staff must make sure
that no-one is left in the boiler.
When entering the boiler and the ducts on the burner side, only electrical operating equipment may be used which, including
the cables and wires, complies with the valid regional electrical regulations.
Lights or electrical manual devices may only be operated at a protective low voltage of up to 42 V. Voltage of up to 400 V
are permitted if the supply comes from an isolating transformer. Low-voltage and isolating transformers must be erected
outside the boiler.
Page 20 of 22
Shell Boilers
C014
Version 7 (12/08)
17.3 Repeated, regular inspections and maintenance by the operating and maintenance staff
The works required are given in the Operating Instructions B007/B010 Checklist Hot water boilers, with the necessary
intervals and should be carried out as described there.
9
Warning! Danger of damage to the boiler. If faults cause controllers or limiters or other safety devices to become
ineffective, the system must be constantly supervised if its operation is continued. If safety devices fail, the
system must if necessary be shut down until suitable assistance has been provided. If the situation is dangerous,
the system must be shut down as a matter of urgency.
17.4 Irregular inspections and maintenance by the operating and maintenance staff
Depending on the water conditioning products used, the method of operation, the operating time and the water conditions,
the owner must set the intervals for the following points. The proposed intervals are the minimum requirements laid down by
Loos International:
17.4.1 Boiler valves and boiler parts

In addition to the operating instructions for the individual sensors, valves and actuators, the following applies:
Hydraulic seals (siphon pipes), display, control and limiter devices should be cleaned and filled with distilled water (halfyearly).
Replace seals on inspection openings in the event of leaks and each time the inspection openings are opened.
Replace parts subject to wear (e.g. level display glass) after the times given in the relevant operating instructions.
Tighten packing glands (weekly) and replace if necessary.
Shaft bearings must be maintained according to their design (sliding or roller bearings) and the operating conditions
(e.g. hot rooms) according to the operating instructions. Roller bearings should generally be maintained after a running
time of 2000 operating hours, i.e. to be cleaned and provided with fresh roller bearing grease (do not fill!), unless
otherwise specified in the relevant operating instructions.
17.4.2 Boiler cleaning on the burner and heating gas side

The heating surfaces on the gas side must be cleaned at certain intervals depending on the fuel, the method of operation
and the operating time each day.
For the simple monitoring of the operating conditions on the flue gas side, it is recommended that the boiler is
opened on the flue gas side after the first three months of operating and the state of the heating surfaces
examined. Further inspections should be carried out at least every year.
Heating pipes should be cleaned with a soot coating of approx. 0.5 mm, ideally with a motor-operated suction brush device.
In addition, any rise in the flue gas temperature above the normal level is a suitable way of determining whether the heating
surfaces should be cleaned on both the gas and the water sides.
17.4.3 Boiler cleaning on the water side

Warning! Danger of damage to the boiler. Deposits on the water side of heating surfaces are dangerous. They
reduce the cooling of the material, which may cause dents in the flame tube or tearing of the flame tube. The
pipe area after the flame tube and other loadbearing parts of the boiler are also at risk.
If the water is treated appropriately, the prescribed dosing agents are used and the system operated correctly, overheating
and corrosion damage will not occur.
The heating surfaces and boiler walls must be free from deposits and corrosion.
For the simple monitoring of the operating conditions on the water side, it is recommended that the boiler is
opened on the water side after the first three months of operating and the state of the inside of the boiler
examined. After a further 9 months, we recommend that the same inspection is carried out. If there are no
deposits and no corrosion, and if the operating log has been kept carefully, further inspections can be carried out
every three years.
Page 21 of 22
Shell Boilers
C014
Version 7 (12/08)
If deposits or corrosion are found, it is recommended that the supplier of the water treatment system or the dosing chemicals
is consulted to determine further measures, e.g. the chemical removal of the deposits. Cleaning on the water side should be
carried out by experienced specialist companies. For chemical cleaning by the owner's operating staff, we recommend
approved boiler scale solvents. If chemical cleaning becomes necessary, this should be noted in the operating log.
Note: Boilers may only be cleaned with boiler scale solvents which are approved under regional regulations. The
regulations on safety and environmental protection must be strictly complied with. These regulations and
instructions are given on the cleaning product containers or in the corresponding safety data sheets. These data
sheets are available from the supplier of the cleaning product.
If corrosion is found, its scope must be determined with the supervisory authority or with the Loos Service engineer. If
necessary, measures to remove the corrosion, or at least to prevent the corrosion continuing, must be taken.
17.5 Repeated, regular inspections and maintenance by experts or competent persons

The scope and the actual work required are listed in the operating instructions B006/B009/B011 Regular inspections with
the necessary time intervals and should be carried out as instructed there. The order-specific overall operating instructions
supplied by Loos International only contain the operating instructions required for the boiler supplied.
Page 22 of 22
Burner
Gas Regulation Module (GRM)

D001
Version 2 (03/04)
Contents
1
Safety .......................................................................................................................................................................... 2
Description of Structure and Function / Description of Process .......................................................................... 2
Technical Data (Dimensions, Weight, Operating Conditions) ............................................................................... 3
Transport and Storage .............................................................................................................................................. 3
8.1
General notes on transport .......................................................................................................................................... 3
8.2
Special transport regulations ....................................................................................................................................... 3
8.3
Interim storage............................................................................................................................................................. 3
Assembly.................................................................................................................................................................... 3
9.1
Place of installation ...................................................................................................................................................... 3
9.2
Assembly staff ............................................................................................................................................................. 4
9.3
Installation.................................................................................................................................................................... 4
9.4
Valves and built-in parts............................................................................................................................................... 4
9.5
Feed and discharge pipes............................................................................................................................................ 5
9.6
Supports ...................................................................................................................................................................... 5
10
Setting and Adjustment............................................................................................................................................. 6
10.1
Leakage test of the gas supply line to the gas regulation module................................................................................ 6
10.2
Leakage test of the assembled gas regulation module ................................................................................................ 6
11
Start-up ....................................................................................................................................................................... 7
11.1
General instructions on carrying out the start-up ......................................................................................................... 7
11.2
Checking the gas connection pressure ........................................................................................................................ 7
11.3
Venting......................................................................................................................................................................... 7
11.4
Adjusting the springs in valves..................................................................................................................................... 8
12
Operation.................................................................................................................................................................... 8
13
Shutting down............................................................................................................................................................ 8
14
Measures in the event of unusual observations and operating faults.................................................................. 8
15
Care and Maintenance............................................................................................................................................... 9
16
Operating Instructions for Burner
Operating Instructions for Pressure Regulator
Page 1 of 9

D001
Version 2 (03/04)
The marginal parameters defined in the technical data of the order confirmation must be complied with. A list of these
parameters is given in Register M. This applies in particular for:
gas characteristics (type of gas, calorific value, gas flow pressure before the shut-off valve at the intake to the gas
regulation module)
ambient parameters: For the gas regulation module, the ambient temperature must be from -10C to +40C. If
necessary, the valves must be protected against radiated heat or temperatures that are too low (risk of embrittlement).
Similar protection must also be provided against moisture, dust and dirt.
Safety

Danger! Gas flowing out uncontrollably can create an explosive mixture of gas and air. This can then explode if
brought into contact with an ignition source.
The gas flow pressure may not exceed the maximum permitted pressure given on the rating plates.
The GRM gas regulation module contains all the valves that are needed for the supply of fuel to the burner on the gas side.
The sequence of the individual valves can be seen in Data Sheet DA038/DA039 in Register M. Using the shut-off valve at
the intake to the gas regulation module, the fuel volume flow can be manually shut off (e.g. for assembly work at the gas
regulation module or for shutting down). The filter valve protects the downstream valves from being soiled by any solids
carried along in the gas. The pressure regulator supplies the burner with the gas flow pressure necessary for safe burner
operation.
A compensator (if necessary) balances out the thermal expansion of the boiler between the cold state and the operating
state. The rear boiler foot (seen from the burner side) is made as the fixed point at the longitudinal support. The front boiler
foot is made as a loose bearing, i.e. the boiler expands forwards when heated up.
In addition, a gas quantity indicator to record the quantity of gas can be integrated into the gas regulating section.
Depending on the gas flow pressure before the shut-off valve at the intake into the gas regulation module, a pressure
safeguard valve (SBV) and a safety shut-off valve (SAV) can be part of the gas regulation module. The pressure safeguard
valve is dimensioned in such a way that if there is a fault in the gas pressure regulator, the flow volume can flow off into the
open without the pressure behind the valve rising impermissibly. The task of the safety shut-off valve is to automatically
shutoff the gas through flow in the gas regulating section if there is any damage to the gas pressure regulator or if the gas
flow pressure at the intake to the gas regulation module is too high, as soon as the pressure in the system to be protected
Page 2 of 9

D001
Version 2 (03/04)
reaches an upper trigger pressure (exceeding the pressure). Instructions for setting the two valves are given in separate
Operating Instructions.
8.1
When transporting the systems, suitable protective measures should be taken, which will depend on the type of transport
chosen. If necessary, Loos International will advise you on the choice of suitable protective measures. In any case, transport
must be carried out with due caution. Unnecessary loads on the components should be avoided. If required, and for a
charge, the delivery can be packed for transport by Loos International and delivered with the appropriate protection.
8.2
Special transport regulations
The following instructions must be followed under all circumstances:
Avoid wet or damp situations
When transporting insulated systems or system components on open vehicles, suitable packaging should be provided to
protect the equipment from the effects of water and weather.
Avoid vibrations as far as possible
Do not under any circumstances expose the systems or system components to temperatures below -20 C (danger of
embrittlement fractures).
For transport by sea, use suitable packaging (overseas containers). If the system is packed in a wooden crate, it may not
under any circumstances be transported on deck.
Make sure that sufficient suitable corrosion protection is provided whatever form of transport is chosen.
8.3
Interim storage
If the module has to be stored, the following instructions must be followed under all circumstances:
Store in a dry (humidity < 60%), dust-free place.
Temperature change in the store < 10 K/h.
Never expose the module to temperatures below - 20C.
If the module is stored insulated and covered with the protective wrapping provided for transport, the protective wrapping
should be cut open at the base for the full length to prevent condensation and thus oxidation on the insulation surface.
Assembly
When setting up and assembling the module and laying the pipes (supply and removal lines), the regionally valid regulations
must be complied with (e.g. building requirements, clear spaces for operation and maintenance, emergency exit routes,
etc.).
9.1
Place of installation
When choosing the place of installation and assembling the gas regulation module, the following rules must be followed:
The operation and maintenance of the boiler, burner and built-on parts may not be restricted.
Access to the inspection openings on the boiler must not be blocked.
The burner and if necessary the boiler door must still be swivellable.
Page 3 of 9

D001
Version 2 (03/04)
In the case of boilers with a swinging front door, a separation point in the connecting line between the burner and the
gas regulation module should be provided in order to allow the door and burner to swing out. If the gas regulation
module is mounted on the door hinge side, an adapter piece must be provided for removal to allow the boiler door and
burner to swing out.
The manual shut-off valve at the intake to the gas regulation module must be freely accessible.
It must be possible to remove and adjust the pressure regulator and, if provided, the safety shut-off valve (SAV) and the
pressure safeguard valve (SBV).
The connecting line between the gas regulation module and the safety shut-off valve at the burner must be made as
short as possible (< 2 m) and in the larger nominal width of the as regulation module and the safety shut-off valve at the
burner in order to keep the pressure losses as low as possible.
Note: If this is not done, it may not be possible for the necessary quantity of gas to flow through and/or there
may be operating problems (unstable operation, "pumping" of the regulator, etc.). If the pipeline between the gas
regulating and burner module cannot be made direct because of the situation on the ground, please contact Loos
International. The gas regulation module and/or the safety shut-off valve must then be made in a larger nominal
width.
If a burner silencer hood is attached (possibly retrofitted), there must be enough space to attach the hood. A straight
piece of pipe must be available to carry out the gas pipe through the hood wall.
9.2
Assembly staff
Assembly of the gas regulation modules may only be carried out by suitably trained specialist personnel who
have the necessary specialist knowledge and who have been authorised by the manufacturer of the system to
carry out this work. Otherwise, the assembly staff must hold the permits required in the regional regulations.
9.3
Installation
To avoid accidents, please follow these instructions on mounting the valves:
Before assembly, remove transport protection or sealing caps.
The supply gas line from the gas transfer station must be connected without tension to the gas regulation module. The
gas regulation module may not serve as a support for the gas supply line.
If assembly welding is required, the valves especially the bellows part of the compensator must be protected against
weld splashing etc. by being covered.
Important: Before starting the work, close the associated shut-off valve in the gas line and secure it to prevent
opening by unauthorised people.
If the gas regulation module was delivered in a dismantled state, for transport reasons, please follow these instructions:
The valves must be arranged in the sequence given in the enclosed Data Sheet (Register M).
The direction of flow for the valves must be noted.

9.4
Valves and built-in parts
Compensator:
When installing the gas regulation module and the connecting pipes to the burner, make sure that the compensator is
handled with care. After assembly, check that the bellows are clean and that the compensator can be shifted.
Important: The compensator is designed for axial forces, and for this reason the compensator may only be
installed parallel to the longitudinal axis of the boiler. Transverse and/or torsional forces must not be allowed to
affect the compensator during assembly or operation.
Page 4 of 9

D001
Version 2 (03/04)
Thermally triggered shut-off valve (TAE):

If a thermally triggered shut-off valve is required, it must be installed before the manual shut-off valve at the intake to the gas
regulation module.
9.5
Feed and discharge pipes
For further information, please read the technical information sheet TI024 Requirements for Boiler Installation Rooms (notes
for the installation of boilers and boiler house components).
Low-pressure supply to the gas regulation module
In the case of a low-pressure supply to the gas regulation module, neither a breather line at the pressure regulator nor a
pressure safeguard blowoff line is necessary (see also Data Sheet DA039 for the gas regulation module in Register M).
High-pressure supply to the gas regulation module:
The enclosed Operating Instructions for the pressure regulator can be used to dimension the breather line at the pressure
regulator and at the pressure safeguard blowoff line.
The breather and blowoff lines must be taken safely into the open air. The two lines may not be combined.
Possibility of venting gas pipe
The Client must provide a way of venting before the gas regulation module ( ND 20).
The vent pipe must be taken safely into the open air. It may not be combined with the breather line or the blow-down line.
9.6
Supports
The scope of delivery of the as regulation module also includes all the supports with connecting elements and four screws
for fixing to the floor (express/ segment anchor screws). With a version with a compensator, a transverse rail is also
supplied.
Fig. 1: Supporting the gas regulation module with sleeve version and flange version
The gas regulation module in the sleeve version is fixed to the supports using round steel brackets and screws on the
adapter pieces. With gas regulation modules in the flange version, the supports are fixed to the flange external diameter
using the screws provided.
The compensator must be installed under pre-tension. After pre-assembly of the supports and after assembly of the
connecting pipes from the gas regulation module to the burner, the support with the transverse rail is fixed to the floor using
the express anchor / segment anchor screws M 12 x 110. The pre-tension when the boiler is in the cold state is 5 mm. The
transverse rail must be installed precisely in the longitudinal axis of the gas regulation module so that the loose bearing can
slide without tension.
The support at the outlet of the gas regulation module to the burner is also fixed to the floor using the express anchor /
segment anchor screws M 12 x 110. If necessary, fixing at the side (e.g. support to the boiler base frame) may be necessary
until the gas supply line is connected.
Page 5 of 9

D001
Version 2 (03/04)

After completing the assembly work, a leakage text must be carried out on the gas regulating section and the valves.
10.1 Leakage test of the gas supply line to the gas regulation module
The leakage test of the gas pipe to the shut-off valve at the gas regulation module must be carried out by the gas supply
company or the contract installation company. Depending on the height of the intake pressure, the corresponding
regulations must be followed. Local regulations may also be applicable.
Important: To protect against excess pressure at the valves of the gas regulation module or at the burner
system, blanking plates or blanking flanges must be installed in the gas pipe before the shut-off valve of the gas
regulation module. If this is not possible, the shut-off valve (note maximum permitted pressure see rating plate)
at the intake to the gas regulation module must be closed. Suitable measures should be taken to ensure that this
valve cannot be opened during the time when the test pressure is applied. Pressure that is too high can fracture
the membrane of the pressure regulator, the safety shut-off valve or the pressure safeguard valve or cause
damage to other valves.
10.2 Leakage test of the assembled gas regulation module

For the leakage test of the valves and the connecting pipes from the gas regulation module to the burner (9), the shut-off
valve (8) and the double shut-off valve (5) must be closed.
1
2
3
4
5
6
7
8
9
Rubber hose with t-piece

Manual pump
Pressure-measuring device (e.g. U pipe, manometer)
Gas throttle
Double shut-off valve
Gas pressure regulator
Filter valve
Shut-off valve
Burner
Test pressure and carrying out the test for the 1st and 2nd test phase:
Test pressure in the valves:
100 - 150 mbar
Waiting time for pressure/temperature balance: 5 minutes

Test time:
5 minutes
Maximum permitted pressure loss:
1 mbar
1st test phase: Shut-off valve (8) to 1st valve seating at the double shut-off valve (5)
The test device is connected to the measurement point of the filter valve (7) and the intake of the double shut-off valve. In
the pressure test, the measurement connection between the individual valves of the double shut-off valve V1 and V2 must
be open.
2nd test phase: Valve space up to the 2nd valve seating of the double shut-off valve (5)
The test device is connected at the space of the double shut-off valve (5).
3rd test phase: Outlet of double shut-off valve (5) to gas throttle (4)
The 3rd test phase can only be carried out during operation using leakage spray.
After the leakage test, all the measurement points must be closed again. The results of the leakage test must be
documented in the usage report.
Page 6 of 9

D001
Version 2 (03/04)
11 Start-up
The following point must be completed before start-up:
Shut-off valves must be checked to see that they move, and their seals and packings, if provided, must be tightened and
checked according to their operating instructions.
At the initial start-up or after work on the valve groups where parts are replaced, a leakage test and venting must be carried
out before the system is started up again.
11.1 General instructions on carrying out the start-up

The initial start-up of components supplied by Loos International may only be carried out by employees of the
company Loos International or by people whom Loos International has expressly authorised to carry out such
work.
Before starting up firings, the conditions given in the special operating regulations must have been met. The firing
capacity must be matched to the boiler steam or heat capacity. The quantity of fuel required for this is given in the Data
Sheet in Register M.
Measurement and control devices must be set according to the individual operating instructions of these components.
Pressure-limiters must react before the pressure safeguard valve. The trigger points of controllers and limiters must be
sufficiently distant from each other and from the limiters.
11.2 Checking the gas connection pressure

The gas connection pressure may not exceed the maximum permitted pressure given on the rating plates of the valves
used.
Before the gas regulation module is vented, the gas connection pressure must be checked. For this, the shut-off valve at the
intake to the gas regulation module is slowly opened and the pressure indicator before the gas pressure regulator is
monitored. Close the shut-off valve immediately if the gas connection pressure exceeds the maximum permitted pressure
for the valves.
Note: If the gas flow pressure does not correspond to the value that is given in the technical data of the order
confirmation in Register M, Loos International must be contacted immediately in any case.
11.3 Venting
Gas must be blown through the pipes and valves in the gas regulation module until the air present or the inert gas has been
pushed out of the lines.
Venting the gas supply line to the gas regulation module:
The gas line as far as the shut-off valve at the intake to the gas regulation module may only be vented by the gas supply
company or by the contract installation company.
Venting the valves of the gas regulation module:
After the pressure test, the valves must be vented. At the measurement point of the double shut-off valve, a hose leading
into the open is attached to remove the air or inert gas. The manual shut-off valve at the intake to the gas regulation module
is opened. The gas in the valves flows through the vent hose into the open. After venting for minutes, the gas regulation
module is guaranteed free of air. After venting, the gas supply should be shut off, the hose removed and the vent connection
closed again immediately.
If the system has a test burner, safe ventilation can also be checked using this burner.
Page 7 of 9

D001
Version 2 (03/04)
11.4 Adjusting the springs in valves

The springs in the pressure regulator, safety shut-off valve (SAV) and pressure safeguard valve (SBV) are not set to the
necessary operating conditions. This must be done as part of the start-up procedure in accordance with the relevant
operating instructions.
12 Operation
Please read the operating instructions:
C001 Quick steam generators or C003 Shell boilers
The gas supply to the gas regulation module is created by opening the shut-off valve at the intake to the gas regulation
module.
13 Shutting down
C001 Quick steam generators or C003 Shell boilers
The gas supply must be interrupted by closing the shut-off valve at the intake to the gas regulation module.

repair:
Observation/fault
Vibration of the gas regulation module
Cause
Repair
Insufficient support of the gas regulation module
Check support and use additional support if

necessary
Valve deflected
check valves in use
Pressure regulator has deflected membrane or

valve rod
check valves in use
Observation/fault
By whom?
Vibration (pumping) of pressure regulator when flow is low
Cause
Repair
Pressure regulator has large nozzle and thus high

flow capacity in comparison with its nominal
connection width. With very low flows, the valve
plate only lifts slightly from the nozzle and is thus
not stable in operation.
Use another spring
By whom?
Page 8 of 9

D001
Version 2 (03/04)
Observation/fault
Vibration (pumping) of pressure regulator when flow is normal
Cause
Repair
Trigger time of pressure regulator is too short,

leading to vibration of the regulator with normal
flows
Throttle pulse line by reducing the pulse line crosssection
Observation/fault
By whom?
In gas operation, the safety shut-off valve closes
Cause
Repair
Burner switches to a load level > low load
Check regulating parameters and switching points
Closure of quick-close fittings in steam network
Close quick-close fittings with a time delay
By whom?

The shut-off valve, the pressure regulating device (including the safety shut-off valve and the pressure safeguard valve if
applicable), the compensator and the gas quantity indicator are maintenance-free.
For general maintenance instructions, please read the operating instructions:
K537 Filter valve
All threaded pipe connections (sleeves) must be sealed in the threads with approved sealing products. Hemp or PTFE
sealing strips are not permitted.
If a connection is undone easily and frequently (separating point), flat-sealing screws with integral sealing must be used.
Only approved sealing products may be used for flange connections too.
To order or inquire about replacement parts, please use the special Ordering/Inquiries form, L006 After Sales Services
which is to be found in File L (Forms).
Page 9 of 9
manual
Installation and operating instructions
M
X6-03
X6-02
X6-01
X7-03
X7-02
X7-01
PE
N
V1
V3
V2
OIL
GAS
min.
PE
X9-02
X4-01
max.
LT
(CPI)
L
X9-03
GAS
OIL
RESET
X4-03
V1
V2
PV
SV
(START)
X10-03
ION
FSV/QRI
PE
N
L
X10-02
FLAME
ALARM
W-FM 200
MOTOR
L
P
Power QRI
QRB
L
FLANGE
LINE
SAFETY
LOOP
12VAC
L
N
G0
X10-01
X3-01 X3-02 X3-03
X9-01
X4-02
IGNITION
L
PE
X8-01
X5-03
PE
O2
module
INT
X8-02
N
V1
3
2
L
PE
L
ON/OFF
X8-03
PE
PE
PE
Start
PE
L
H0-Start
X5-02
SV
PE
min
PE
Start
X5-01
PE
min
X3-04
PE
L
N
LINE
VOLTAGE
F1/T6,3
IEC 127-2/V
F2/T4
IEC 127-2/V
F3/T4
IEC 127-2/V
info
esc
Weishaupt Combustion Manager W-FM
83054802 - 1/2004
General instructions
Safety instructions
Technical description
3.1 Function
3.2 Display and programmer unit ABE
6
6
7
Installation
4.1 Safety instructions for installation
4.2 Installation of components
4.3 Electrical connection diagram
(principle drawing)
8
8
8
10
Preparation for commissioning

5.1 Safety instructions
5.2 Steps to be taken on burner
and frequency converter
5.3 Preparation steps on
combustion manager
16
16
Commissioning - modulating
6.1 Set fuel and load points on W-FM
6.2 Commission burner
6.2.1 Set mixing pressure for ignition
6.2.2 Burner ignition
6.2.3 Set load point 1
6.2.4 Start full load
6.2.5 Optimise full load
6.2.6 Redefine intermediate load points
6.3 O2 functions - modulating
6.3.1 Set O2 sensor
6.3.2 Set O2 control
6.3.3 Set O2 regulating functions
6.3.4 Check and optimise O2 control
6.3.5 Optimise O2 control
6.4 Concluding work following
commissioning
6.4.1 Set ratings range and flue gas
temperature limit values
6.4.2 Concluding work on the burner
18
18
19
19
20
21
22
23
24
26
26
27
28
28
29
Commissioning multi-stage
7.1 Set fuel and required rating
7.2 Adjust burner
7.2.1 Pre-set curve parameters
7.2.4 Set switch off point(s)
7.2.5 Check operating, switch on
and off points
7.2.6 Check start behaviour
7.2.7 Define full load as required load
16
16
30
30
31
32
32
33
33
34
35
36
36
37
37
Load controller
8.1 Set operating mode
8.2 Configure sensors
8.3 Set point (external)
8.4 Set point (internal)
8.5 Modulating load control
8.5.1 Parameter internal load control
8.5.2 Optimise internal load control
8.6 Multi-stage load control
8.7 Cold start function
38
38
39
40
41
42
42
43
44
45
Parameter and functions

9.1 Menu structure (ABE)
9.2 Operating display
9.3 Operation
9.4 Manual operation
9.5 Burner control
9.5.1 Times
9.5.2 Configuration
9.5.3 Product identification and
software version
9.6 Ratio control
9.6.1 Setting gas/oil
9.6.2 Times
9.6.3 Switch off behaviour
9.6.4 Programme stop
9.7 O2 control and guarding
9.7.1 Setting gas/oil
9.7.2 Process data
9.8 Load controller
9.8.1 Control parameter
9.8.2 Temperature switch
9.8.3 Cold start
9.8.4 Configuration load controller
9.8.5 Adaption
9.8.6 SW version
9.9 AZL (ABE)
9.9.1 Times
9.9.2 Language
9.9.3 Date format
9.9.4 Physical units
9.9.5 eBus
9.9.6 Modbus
9.9.7 Display contrast
9.9.8 Serial number and SW version
9.10 Stepping motors
9.10.1 Addressing
9.10.2 Rotation direction
9.11 FC module
9.11.1 Configuration
9.11.2 Process data
9.12 O2 module
9.12.2 Display values
9.13 System configuration
9.14 Operating hours
9.15 Start counter
9.16 Fuel meter
9.17 Updating
9.17.1 Parameter back-up
9.17.2 Load SW from PC
9.18 Password
9.19 TV test
9.20 Sequence of operation diagrams
46
46
54
54
55
56
56
56
56
57
57
61
61
61
62
62
64
65
65
66
67
68
71
71
72
72
72
72
72
72
73
73
73
74
74
74
74
75
75
76
76
77
77
77
77
78
78
79
79
80
80
80
80
80
81
10 O
sensor
86
converter
88
11 Frequency
11.1 Programming and display unit frequency
converter VLT series
11.2 Parametering VLT 2800
11.3 Parametering VLT 5000
12 Cause and rectification of faults

13 Maintenance
13.1 Safety information for maintenance
13.2 Maintenance plan
data
14 Technical
14.1 Combustion manager W-FM
88
90
92
94
105
105
105
14.2 Servomotor SQM45.../48...

14.3 Flame guarding
14.4 Display and operating unit (ABE)
106
106
107
108
109
Appendix
Notes
110
General information
These installation and operating instructions

are an integral part of the equipment and must be
kept permanently on site.
are to be used by qualified personnel only.
contain the relevant information for the safe assembly,

commissioning and servicing of the equipment.
are for the attention of all personnel working with the

equipment.
in addition to this installation and operating manual,

the documentation for the relevant burner and the
type of frequency converter must be observed.
Explanation of notes and symbols

This symbol is used to mark instructions,
which, if not followed, could result in death or
serious injury.
DANGER
Hand-over and operating instructions

The contractor is responsible for passing the operating
instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these instructions should be kept with the heating appliance. The
address and telephone number of the nearest service
centre should be entered on the reverse of the operating
instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
inspect the plant at least once a year. To ensure regular
inspections, -weishaupt- recommends a service contract.
The contractor should instruct the plant operator in the use
of the equipment prior to hand-over and inform him as and
when necessary of any further inspections that are required
before the plant can be used.
Guarantee and liability
Weishaupt will not accept liability or meet any guarantee
claims for personal injury or damage to property arising as
a result of one or more of the causes below:

which, if not followed, could result in life
threatening electric shock.
DANGER
ATTENTION

which, if not followed, could result in damage
to, or the destruction of the equipment and
environmental damage.
This symbol is used to mark procedures,

which you should follow.
1.
2.
3.
Procedures with more than one step are

numbered.
This symbol is used when you are required to

carry out a test.
This symbol is used to list points.
This symbol indicates detailed information
Abbreviations
Tab.
Table
Ch.
Chapter
Failure to use the equipment as intended

Improper assembly, commissioning, operating or
servicing of the equipment.
Operating the appliance with defective safety
equipment, or with non-recommended or nonfunctioning safety and protection devices
Failure to follow the information in the Installation and
Alterations made to the construction of the equipment
by the plant operator
Fitting additional components not tested or approved
for use with the equipment.
Alterations made to the equipment by the plant
operator (e.g. motor ratio - rating and speed)
Alterations made to the combustion chamber, which
hinders constructive, predetermined flame formation
Inadequate guarding of parts liable to wear and tear
Improperly executed repairs
Acts of God
Damage caused by continued use despite the
occurrence of a fault
Use of incorrect fuel
Obstruction or damage of the supply lines
Use of non-original -weishaupt- spare parts
2 Safety information
Dangers when using the equipment
Weishaupt products are manufactured in accordance with
the relevant existing standards and guidelines and the
recognised safety laws. However, improper use of the
equipment could endanger life of the user or a third party,
or result in damage to the plant.
To avoid unnecessary danger, the equipment is only to be
used:
for its intended purpose
under ideal safety conditions
with reference to all the information in the installation
and operating instructions
in accordance with inspection and service work.
Faults, which could affect the safe operation of the burner,
should be rectified immediately.
Personnel training
Only competent personnel may work on the appliance.
Competent personnel according to this operating manual
are persons who are familiar with the installation,
mounting, setting and commissioning of the product and
have the necessary qualifications such as: Training, instruction or authorisation to switch electrical
circuits and electrical devices on and off, to earth them
and to mark them in accordance with the safety
standards.
Training, instruction or authorisation to carry out
installation, alteration and maintenance work on gas
installations in buildings and on site.
Organisational measures
Everyone working on the plant should wear the
necessary protective clothing.
All safety devices should be checked regularly.
Informal safety measures
In addition to the installation and operating instructions,
local codes of practice should also be adhered to.
Special attention should be paid to the relevant
installation and safety guidelines given.
All safety and danger notices should be kept in a
legible condition.
Furthermore, all safety documentation and danger
notes covering the frequency converter and burner
must be observed.
2
Electrical safety
Before starting work - isolate plant and protect against
reactivation, check voltage is isolated, the unit is
earthed, and protected from adjacent equipment that
might still be under voltage!
Work on the electrical supply should be carried out by
a qualified electrician
Electrical components should be checked during
servicing. Loose connections and heat damaged
cables should be dealt with immediately.
The control panel should be locked at all times. Access
should be restricted to authorised button holder
personnel.
Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed
and tools to EN 60900 must be used. A second
person should be present to switch off the mains
supply in an emergency.
Maintenance and fault rectification
Necessary installation, service and inspection work
should be carried out at the specified time.
Inform the operator before beginning any service
work.
For all service, inspection and repair work, electrically
isolate the equipment and ensure the mains switch
cannot be accidentally switched back on. Cut off the
fuel supply.
Flame guarding devices, limit controls, correcting
elements and all other safety devices must be
commissioned by, and may only be replaced by, the
manufacturer or an authorised agent.
Following service work, all safety devices should be
tested to ensure they are functioning correctly.
Alterations to the construction of the equipment
No alterations to the equipment are to be made without
the approval of the manufacturer.
All conversions require written confirmation from Max
Weishaupt GmbH.
Any parts not in perfect working order should be
replaced immediately.
No additional components may be fitted, which have
not been tested for use with the equipment.
Use only -weishaupt- replacement and connection
parts. Parts from other manufacturers are not
guaranteed to be suitable to meet the necessary
operational and safety requirements.
Safety measures in normal operation

Only use the equipment when all the safety devices are
fully functional.
The moving parts of the burner should not be touched
during operation.
At least once a year the equipment, including the safety
devices, should be checked for signs of visible damage
and to ensure that the safety devices are operating
correctly.
More frequent safety check may be required
depending on plant conditions.
Technical description
The combustion manager W-FM contains all functions

required for safe and efficient operation of multi-stage or
modulating single fuel and dual fuel burners.
The display and programming unit shows the conditions
and allows programming via dial knob and function
buttons.
Functions
Burner control
Electronic compound regulation for up to a max of
5 1 stepping motors
Speed control
O2 control
Valve proving
True dual fuel operation
Integral load/ratings controller 2
Flame guarding
Separate ABE programmer
3.1 Function
Combustion manager
The combustion manager:
controls the sequence of operation
guards the flame
communicates with the stepping motors
controls and guards the frequency converter
carries out valve proving of the gas valves
has: an integrated load controller 2
Speed control 1
O2 control 1
Operating elements
The system can be controlled by several operating units:
a plug-in programmer ABE
PC module for guard control
Remote main control system (Building Management
System)
Flame sensor
Guards the flame during all phases of operation. If the
flame signal does not correspond to the sequence of
operations, a safety lockout will occur.
Flame sensors used:
QRI for continuous or intermittent operation for oil,
gas and dual fuel burners.
Ionisation electrode only for gas for continuous or
intermittent operation.
Stepping motors
Separate stepping motors (as appropriate) on:
Air damper
Oil controller
Gas butterfly valve
Mixing head
Providing precise, direct control of the correcting elements
in the compound.
Individual setting values are transmitted via CAN BUS from
the combustion manager to the stepping motors, the
stepping motors are electronically adjusted and the
combustion manager constantly guards their position
return signals.
1
2
only W-FM 200

optional on W-FM 100
Load controller 2
The optional, integrated PID load controller can be used as
a temperature or pressure controller for multi-stage or
modulating burners, depending on the connection and
parametering. Furthermore the load controller contains a
control reaction damper which protects the stepping
motors from unnecessary drive impulses, thus protecting
the stepping motors and increases their life span.
The load controller can be operated with one external
setting value or set point input, or with two internal set
points.
The internal set points can be selected using an external,
potential free contact.
Switchover from an external operation to the internal load
controller is via a contact.
A separate start up programme is incorporated for boiler
cold start if required.
Speed control 1
The frequency converter of the fan motor is started by a set
point output (0/4 - 20 mA) and the speed is matched to
the current burner rating required. The speed and the
rotation are determined and guarded using an inductive
proximity switch in conjunction with an asymmetrical
transmitter disc. In compound with the stepping motors
the required combustion air is automatically adjusted and
the electrical consumption is reduced to a minimum.
If the air supply fails or becomes insufficient, an air
pressure switch initiates lockout.
O2 Trim control 1
The residual O2 content in the flue gas is determined by a
sensor, which compares it to the set points calculated
during commissioning. Depending on the control
deviations from the set points, the combustion manager
re-adjusts the air regulating devices and corrects the
burners aeration.
Low gas programme
If the control gas pressure falls below the setting of the low
gas pressure switch during operation, the combustion
manager starts a low gas programme.
If the gas pressure is below the set point prior to start, the
burner start is inhibited.
3
Valve proving (only on gas operation)
Following each controlled shutdown, the combustion
manager carries out a valve proving test of the gas
solenoid valves.
Following lockout or power failure, the valve proving test is
carried out prior to the next burner start.
Sequence diagram valve proving
Function
1st. Test phase:
During a controlled shutdown valve V1 closes
immediately, and valve V2 has a slight delay in closing
which permits the volume between the valve seats to
depressurise. The section between V1 and V2 must
remain depressurised once the second valve has
closed.
Valve V2
1st. Test phase
2nd. Test phase
3 secs.
sek.
3 secs.
sek.
Valve V1
10sek.
secs.
10
10sek.
secs.
10
P between
V1 and V2
Gas press.
switch VP
Setting pressure gas pressure switch

2nd. Test phase:
Valve V1 opens and immediately closes again,
allowing gas pressure build-up between V1 and V2
valve seats. During the test phase, the pressure
between the valve seats must not fall below the
pressure setting of the gas pressure switch XX.
PR +
PV
= setting pressure
2
PR = Control pressure into V1 (reduce impact pressure)
PV = Maximum pressure during pre-purge downstream of V2
3.2 Display and programmer unit ABE

Setting without tools
The advantage of electronic ratio control provided by the
W-FM lies in the simple setting via display menus. The
positioning for fuel, air, and auxiliary actuators is selected
digitally. With only a few input ratings-positions being
entered, the intermediate firing positions are automatically
interpolated.
Display and programmer unit ABE
Display
4 lines with scroll function
ESC button
Cancel or return
Info button
Return to operating display
Enter button
Execution
Scroll knob
Cursor control and value change
RS 232 interface (COM1)
For PC or Laptop connection
CAN Bus
Connection to W-FM
RJ45 interface for eBus/Mod Bus (COM2)
Emergency - Off function

Simultaneous pressing of the ESC and Enter buttons
immediately initiates lockout. The Emergency - Off function
is saved in the lockout history.
Contrast adjustment
To change the contrast of the display, press Enter button
and hold down whilst changing the contrast using the
scroll knob (+/). (Only possible in menu Normal
operation, contrast adjustment with saving see Ch. 9.9.7).
7
Installation
4.1 Safety instructions for installation

Electrically isolate the plant
Prior to installation switch off the mains switch
and the safety switch.
Failure to comply could cause death or
serious injury by electric shock.
DANGER
Note
Due to the frequency converters used it is

possible for some of the electrical
components to continue to be energised
following mains isolation. The waiting time
given must therefore be observed prior to
starting work.
4.2 Installation of components

The electrical connections should be carried out to the
wiring diagram supplied with the burner. All country and
local codes of practice (i.e. EN, DIN, VDE, BS, etc.) must
be observed.
Line length
The line length of the individual components to the W-FM
can be a maximum of 100 m.
When installing the stepping motors and the ABE it is
particularly important that the total line length of all Bus
connections (CAN-Bus) does not exceed 100 m.
Display and programmer unit ABE

The installation of the ABE to the W-FM is carried out with
a special CAN-Bus cable. This cable supplies voltage to
the ABE and transmits the BUS signals.
Stepping motors
The installation is carried out as a serial Bus system.
Air damper
Gas butterfly valve
Oil controller
Mixing head
The voltage supply of the stepping motors and the
communication with the W-FM is carried out via CAN-Bus
cable.
Frequency converter (only W-FM 200)

The electrical connection of the frequency converter has to
be carried out to the wiring diagram supplied with the
burner. When wiring, ensure that the screens of the cable
are connected only once to the W-FM (FE terminal).
Flame sensor
The 1.8 m senor line to the flame sensor can be extended
by up to 100m if installed separately (i.e. for W-FM in a
separate control panel).
Ignition line
The ignition cables should be installed as close as
possible to the ignition electrodes. Ignition cables must
have an adequate spacing away from any other wiring.
Gas valve train

The pre-wired gas valve train should be connected as per
the wiring diagram supplied with the burner. Cable entry is
via the cable entry access on the right of the burner.
External connections
Mains voltage carrying lines (230V; 50 Hz) should be
flexible and have a minimum cross section of 0.75 mm. The
PE terminals on the fixing plate of the W-FM should be
used for earth wire connection.
O2 sensor / O2 module (only W-FM 200)

The electrical connection of the O2 sensor or O2 module
should be carried out to the wiring diagram supplied with
the burner. Please note that the screened sensor line of
the O2 sensor must be connected separately and line
length must not exceed 10 m.
Installation O2 sensor see Ch. 10.
Bus connection
On last component of the Bus line, a Bus connection
should be made using the jumper supplied. On all other
components within the Bus, the Bus termination jumper
must not be connected.
On the ABE the Bus connection is inbuilt.
4
Installation example: W-FM in burner housing
(only W-FM 200)
with Bus
connection
Jumper
O2-Modul
with Bus
connection
SQM4...
no Bus
connection
SQM4...
no Bus
connection
(only W-FM 200)
Burner
Burner
Frequency
converter 2
GND
CANL
CANH
AC2 12V
AC1 12V
SQM4...
no Bus
connection
AC1 12V 4 AT
GND
AC2 12V 4 AT
SQM4...
no Bus
connection
2 AT
SQM4...
no Bus
connection
GND
CANL
CANH
AC2 12V
AC1 12V
SQM4...
no Bus
connection
GND
CANL
CANH
AC2 12V
AC1 12V
4 AT
4 AT
ABE
3
6,3 AT
5
W-FM
GND
CANL
CANH
AC2 12V
AC1 12V
ABE
Jumper
GND
CANL
CANH
O2 module
Installation example: W-FM in a control panel
Netz
4 AT
4 AT
5
6,3 AT
(only W-FM 200)
W-FM
Frequency
converter
Frequency
converter 1
Mains
5
(only W-FM 200)
Frequency converter
Frequency
converter
W-FM fitted into a control panel

A second supply transformer is required for the Bus supply
if distance between W-FM and burner is an extended
distance. The supply transformer 2 is fitted to the burner
and connected to the burner terminal rail. The voltage
supply of all following Bus components is exclusively via
supply transformer 2.
The voltage supply (AC1 and AC2) must not be connected
to the bus line from W-FM to burner terminal rail.
Bus line W-FM to control panel order number: 743 192.
KX
L N
SX
FX
L PE N L
1
X30-01
X3-04
X10-01
X3-01
12V
230V
Safety circuit
1
2
Burner lockout
12V
12V
1
2
3
4
3
2
SX
X52
KX
Additional connections
External connections
PE
230V 1/N/PE 50-60Hz N
L
F10
X3-02
SX
FX
S7
L
L
T1
PE N
L
L
L
(F10)
Y9
L N PE
X36
P<
PE 2
PE
L
1
1
3
3
F36
X35
P>
1
1
3
3
B3
Pt/Ni1000
B3
Pt100
Y7
PE N L
1 3
B3
P20W/P30W
Legend:
A1 Combustion manager
B3 Appliances temperature/ pressure sensor
F10 Air pressure switch
F35 Max. oil return pressure sensor
F36 Min. oil supply pressure sensor
S7 Burner flange limit switch
T1 Ignition unit
T2 Control transformer
Y7 Magnetic coupling
Y9 Solenoid valve on air pressure switch
Y10 Anti siphon fuel valve
FE certified earth
Y10
FE
F35
PE 2
PE
X5-02
X4-01
X30-02
Burner on
ext. controller
contacts
1
2
3
4
Pre-selection Gas
Pre-selection Oil
X5-03
1
2
Burner reset
X3-03
1
2
3
4
X4-02
Start release Oil
1
2
X6-01
X7-03
1
2
1
2
3
4
Residual oil immediate

start
X4-03
1
2
Start release Gas
X6-03
3
2
1
X8-01
2
3
3
2
1
1
2
3
4
Motor start
contactor
X61
1
2
X60
X6-02
5
4
3
2
1
1
2
3
5
4
3
2
1
FE
0
4 - 20mA0
0 - 10V
Power Sensor
W-FM 200
5
4
3
2
1
FE
0
4 - 20mA0
0 - 10V
T2
X63
X5-01
1
2
Gas operation
Oil operation
1
2
3
4
Return signal motor

protection contact
FE 3
0 2
4 - 20mA0
1
10
X30-03
4.3 Electrical connection (principle drawing)

X60/X61 = actual value
X62
= Set point
X63
= Plotter output
Function X60 - X63 only
with internal load controller
Set point switchover or

operating type switchover load controller
X62
On multi stage
Light-oil burners
size 30 - 40
On multi stage
Heavy-oil burners
size 30 - 50
X7-01
X7-01
Y13
PE N L
Y11
Legend:
Y11 Partial load solenoid valve
Y12 Intermediate load solenoid valve
Y13 Full load solenoid valve
Y14 Additional solenoid valve
Y15 Additional solenoid valve
PE N L
1
2
3
X7-02
X7-02
1
2
3
1
2
3
1
2
3
Y12
X8-02
Y12
N PE
1
2
3
4
Y14
(U /2)
Y14
X8-03
X8-03
L
N PE
Y15
(U /2)
On modulating
Light-oil burners
sizes 30 - 70
On modulating
Heavy-oil burners
sizes 30 - 70
1
2
3
4
(Option)
1
2
3
4
Y11
Y12
Y14
Y15
X7-01
Y11
Y11
(UN/2)
Y11
PE N L
N PE
(UN/2)
Y12
Solenoid valve/nozzle solenoid

Solenoid valve (normally open)
Additional solenoid valve
Additional solenoid valve
X8-02
Y14
(U /2)
Y14
(U /2)
X8-03
X8-03
1
2
3
1
2
3
4
1
2
3
4
N PE
1
2
3
4
Y11
(UN/2)
Y15
(UN/2)
Y15
W-FM 200
11
BK
BN
BN
B20
BN
B20
X70
BU
X71
BU
1
2
3
4
5
1
2
3
4
BU
B12
X72
B21
B21
BN
X73
0/4-20
mA out
Connection
frequency converter
+24V
Start frequency converter
Lockout frequency converter
1
2
3
4
BU
12-24V
DC in
1
2
3
4
5
6
12
Set point
Earth
Screen
B12
Legend:
B12 Proximity switch burner motor
B20 Fuel meter Gas (optional)
B21 Fuel meter Oil (optional)
W-FM 200
X10-02.1
BN
P<
X21-01
X22-01
X21-02
braun
F11
P>
F33
P>
F12
9
8
4
3
X10-02.2
L1
4
3
9
8
X23-01
X8A
3
BK
X8B
2
7
7
2
X10-03
X8
1
6
6
1
1
PE
1
2
3
4
5
X22-03
X70
X50
2
blue
PE
3
L1
X9-02
3
L1
X20-02
2
PE
1
10
black
Connection control panel

External signalling pressure switch (optional)
5
4
5
4
4
3
X23-03
2
3
4
5
6
L2
X22-02
PE
2
3
3
2
1
1
1
PE
2
X23-02
L2
X9-03
X20-03
L2
8
4
7
2
3
4
1
2
3
4
5
6
X9-01
X20-01
2
1
1
2
PE N
Y2
X9
X24-01
1
PE
B1
X9A
3
Y20
Terminal box gas valve train
4
L2
QRI
X24-02
X72
1
PE
Bus interface
Y1
2
L1
X51
3
L1
N
1
3
4/6
5
7
X24-03
A2
Y3
B1
QRB
3
N
1
2
3
4
5
6
3
B1
A2
B1
F11
F12
F33
Y1
Y2
Y3
Y17
Y18
Y19
Y20
Only with O2 control (optional)
Connection O2 module
Y18
Display unit/programmer
Flame sensor
Low gas pressure switch
Valve proving pressure switch
High gas pressure switch
Ignition gas solenoid valve
Main gas solenoid valves
Remote solenoid valve
Oil controller stepping motor
Gas butterfly stepping motor
Mixing head stepping motor
Air damper stepping motor
Legend:
W-FM 200
Y19
Y17
13
L N PE
B11
Pt/Ni1000
B10
1
2
3
Pt/Ni1000
X83
X86
X89-01
X88
6
5
4
3
2
1
1
2
3
L N PE
3
2
1
1
2
3
X82
X85
3
2
1
3
2
1
X87
X89-02
QGO20
O2 module
X81
Mains voltage
Connection stepping
motor
X84
Q4
Q5
PE
3
2
1
12VAC1
12VAC2
CANH
CANL
GND
1
2
3
4
5
U3
G2
M
B2
M
B1
6
5
4
3
2
1
12VAC1
12VAC2
CANH
CANL
GND
14
1
2
3
4
5
O2 sensor
B10 Combustion air temperature sensor

B11 Flue gas temperature sensor
Legend:
Usensor
X70
MOTOR SPEED INPUT
X71
X72
FUEL COUNTER INPUT
X5-03
X4-01
X4-02
X4-03
X3-01 X3-02 X3-03
L
N
PE
L
LINE
VOLTAGE
PE
M
F1/T6,3
IEC 127-2/V
Start
L
H0-Start
F2/T4
IEC 127-2/V
X10-01
F3/T4
IEC 127-2/V
12VAC
G0
QRB
LINE
X10-02
SAFETY
LOOP
FLANGE
Power QRI
GND
X51
Shield
12VAC1
12VAC2
CANH
CANL
GND
Shield
12VAC1
12VAC2
CANH
CANL
M
12VAC1
BUS
ALARM
PE
Pt/Ni1000
PE
MOTOR
X10-03
ION
X9-01
FSV/QRI
FE
12VAC2
Pt100
(START)
SV
X60
L
L
PV
V2
FE
0-10V
Power Supply
Sensor
4-20mA
FE
0-10V
4-20mA
FE
TEMP.
PE
V1
PE
max.
LT
(CPI)
L
N
X9-02
RESET
IGNITION
X9-03
PE
FE
GAS
min.
OIL
OIL
GAS
X8-01
0/4-20mA Setpoint OUT
INT
V1
L
PE
0
4-20mA
TEMP./PRES.
INPUT
X61
12-24VDC Alarm in
X5-02
Start-OUT
X5-01
3 Wire-PNP
SV
OIL
V1
PE
X8-02
FE
Pulse-IN
ON/OFF
X7-01
V2
2 Wire
Start
GAS
X7-02
FE
SET POINT
INPUT
X62
Usensor
X7-03
OIL
X6-01
X8-03
FE
PE
min
X6-02
3 Wire-PNP
X6-03
2 Wire
PE
min
N
Pulse-IN
Usensor
2 Wire
3 Wire-PNP
LOAD
OUTPUT
X63
FE
Reserve
Pulse-IN
TRAFO
X52
X50
BUS
PE
FLAME
PE
V3
W-FM
PE
L
X3-04
FREQUENCY CONVERTER
X73
15
Preparation for commissioning
5.1 Safety note

Check installation
All installation work must be completed and
checked prior to commissioning. The burner
must be mounted on the appliance, ready for
operation and all control and safety devices
DANGER must be connected correctly.
Safety notes on initial commissioning

The initial commissioning must only be carried out by the
supplier, manufacturer or their appointed agent. At this
time, all the control and safety equipment must be
checked to ensure correct operation and, if it can be
adjusted, it should be checked that it has been set
correctly.
Burner mounted, including refractory as required

Fuel supply complete
Electrical connections and controls complete
Furthermore the correct fusing of the circuits and the

measures for contact protection of electrical equipment
and of all wiring must be checked
5.2 Preparation on the burner and the frequency converter

Burner
Check setting on burner, vent fuel lines and connect
measuring instruments.
If the burner is fitted with a moving mixing head (with
stepping motor), this should be checked for freedom of
movement.
Additional data relating to the burner and frequency

converter can be found in the relevant installation and
Frequency converter 1 (only for Danfoss VLT...)

Check parameter settings on frequency converter (see
parameter list Ch. 11).
Carry out automatic motor adaption on frequency
converter using parameter 107 (not possible on all
frequency converters).
Note Due to the automatic motor adaption, the motor-slip
adjustment and the load compensation are set
back. These parameters must be re-set to the weishaupt- data (parameter 134, 136 on VLT 2800
or 113, 114 and 115 on VLT 5000).
5.3 Preparation on the combustion manager

1. Burner OFF
To be able to carry out the following steps it is necessary
to set the burner to OFF in menu Manual Operation.
Burner Off
2. Enter password
By asking for a password it is ensured that only authorised
personnel have access to the configuration and setting
parameter.
Enter digit or number using the dial knob at the flashing
cursor point and confirm with <ENTER>.
Corrections can be made using <ESC>, empty data
spaces should be filled using <ENTER>.
Enter password
16
W-FM 200 only when used with frequency converter
Manual Operation
Auto/Manual/Off
Auto/Manual/ Off
Curr: Automatic
New: Burner Off
Enter PW
Access SERV
Enter
password
:........
-
Ch. 9.4
Ch. 9.18
5
3. Carry out speed control standardisation 1
During speed control standardisation a set point signal of
95% is given. The speed is determined and saved in
parameter Standardised Speed. If, during standardisation
more than 50Hz is displayed, the motor-slip compensation
(=0) on the frequency converter has to be checked.
The rotational direction of the motor should be checked
during speed standardisation.
Note After each speed standardisation, or changes to the
saved values, the combustion quality needs to be
checked.
4. Check configuration of O2 module 1
The following parameter should be check and set for
operation with O2 trim control.
O2-Sensor:
QGO20
Supply air sensor:PT1000 (if fitted)
Flue gas sensor: PT1000 (if fitted)
MaxTempFlueGas: Presetting 400 C
5. Check O2 sensor temperature 1

The O2 sensor requires an internal operating temperature
of 700 C (15C). If the sensor has been connected
incorrectly, this can lead to overheating and thus damage
of the sensor. If the sensor temperature exceeds 750 C,
the sensor should be isolated and the electrical
connection should be checked.
Speed standardisation
Parm + display
FC module
Configuration
Speed control
Standardisation
Standardisation
Curr: deactivated
New: activated
Ch. 9.11.1
O2 module configuration
Parm + display
O2 module
Configuration
O2 sensor
SupAirTempSens
FlueGasTempSens
MaxTempFlGas
Ch. 9.12.1
Check O2 sensor temperature

Param + Display
O2 module
Displayed values
QGOSensorTemp
QGOHeatingLoad
Ch. 9.12.2
Note The QGOSensorTemp and QGOHeatingLoad

should be guarded regularly during the heat up
process.
HeatingLoad: Start heating load to 100 C ___approx. 13%
Heat up process ____________approx. 60%
Operating temperature: __approx. 15 25%
6. Deactivate O2 trim control 1
For commissioning the O2 trim control for the individual
fuels, the O2Ctrl should initially be deactivated.
The O2 controller and the O2 guard have no influence on
the burner operation at this setting.
Note On dual fuel burners the O2 trim control should be
deactivated on both fuels.
7. Enter fuel type

To be able to calculate the combustion efficiency it is
necessary to define the type of fuel used.
If a fuel is used which is not available for selection, its fuel
specific values can be entered under Fuel type def.
Note On dual fuel burners both the oil and gas type must
be entered.
Automatic O2 trim control deactivate

Param + Display
O2Ctrl/GuardDeac
t Setting ...
OperatingMode
OperatingMode
Curr: man deact
New: man deact
Ch. 9.7.1
Enter fuel type

Param + Display
O2Ctrl/Guard
Setting ...
Fuel type
Fuel type def.
Ch. 9.7.1
only W-FM 200 in connection with frequency

converter or O2 module
17
Commissioning - modulating
6.1 Set fuel and load limits on W-FM

Select fuel (only on dual fuel burners)
Select the required fuel using the external fuel selection
switch. If an external fuel selection switch is not available,
fuel selection is made using the ABE or BMS.
Note The external fuel selection switch takes priority. That
means the commissioning can only be carried out
with the fuel set at this switch.
Check load limits

To ensure that the whole ratings range is available for
commissioning, check load points and adjust if necessary.
MinRating: _______________________________ 0,0 %
MaxRating: _______________________________ 100 %
Note On dual fuel burners the load points for oil and gas
should be checked. On single fuel oil and gas
burners only one fuel appears in the display.
18
Select fuel
Operation
Fuel
Fuel selection
Fuel selection
Curr: Oil
New: Gas
Ch.9.3
or:
Fuel selection
switch on Oil
Load limits
Param + Display
RatioControl
GasSettings
LoadLimits
MinLoadGas
MaxLoadGas
Ch. 9.6.1
6
6.2 Commissioning the burner
6.2.1 Set mixing pressure for ignition
Set Program stop 36
Prior to the first ignition trial, the program stop must be set
to 36 IgnitionPos. After burner start the burner runs to the
ignition position without actual ignition occurring.
Note In its delivered condition the program stop has
already been factory pre-set to 36.
Open manual fuel shut off devices and the burner is

ready to start
After the fuel shut off devices have been opened the
burner should be started in manual operation.
Note For burner start all safety devices, pressure and
temperature controllers should be in operating
position.
Ensure sufficient heat requirement for the duration
of the commissioning procedures.
Set ignition position
Set the ignition positions whilst observing the mixing
pressure.
The speed during ignition should not be less than 80% for
oil and 70% for gas (only when using a frequency
converter / W-FM200).
If the measured mixing pressure is too high, this can be
adjusted by reducing the air damper position.
The relevant ignition pre-settings should be taken from the
installation and operating instructions of the burner or its
test data sheet.
Note The auxiliary motor position on 3LN burners
(multiflam) in ignition position and during burner
operation must be a minimum of 18.
Program stop 36: Ignition position without ignition

RatioControl
ProgramStop
ProgramStop
Curr: 36 IgnitionPos
New: 36 IgnitionPos
Ch. 9.6.1
Burner On
RatioControl
Auto/Manual/Off
Auto/Manual/Off
Curr: Burner Off
New: Burner ON
Ch. 9.3
Ignition positions (example gas operation 3LN multiflam)

RatioControl
GasSettings
SpecialPositions
IgnitionPos
IgnitionPosGas
IgnitionPosAir
IgnitionPosAux
IgnitionPosFC
Ch. 9.6.1
IgnitionPosGas
Curr: 10.5
New: 15
IgnitionPosAir
Curr: 13
New: 10
IgnitionPosAux
Curr: 18
New: 19
IgnitionPosFC
Curr: 100%
New: 70%
19
6
Set program stop 52
To ignite the burner the program stop should be set from
36 to 52. Fuel is released following
pre-ignition. The motors remain in the ignition positions
setting.
Pre-set fuel pressure

On oil and dual fuel burners the oil throughput for full load
has been measured, that means the pump pressure has
been factory pre-set (20-30 bar) and should only be
adjusted if starting problems occur.
The gas setting pressure can be found in the installation
and operating instructions of the burner.
Carry out combustion analysis
Determine CO, O2 values and carry out smoke
measurement. If necessary, optimise combustion by
adjusting the ignition positions.
20
Program stop 52: ignition after safety time

SpecialPositions
ProgramStop
ProgramStop
New: 52 Interv 2
Ch. 9.6.1
6
6.2.3 Set load point 1
Deactivate program stop
To continue with commissioning the program stop has to
be deactivated. If the program stop is not deactivated, the
burner remains in the position set and setting of additional
load points is not possible.
Deactivate program stop
Set load point 1

In setting oil, the first load point has been programmed by
the factory.
If the first load point has been deleted, the ignition load
values will be taken over automatically as the first load
point just as with Setting Gas.
In both cases the values should be matched and a
combustion analysis should be carried out.
Take over Ignition load point as load point 1
Procedure:
1. Drive up the air damper stepping motor until a residual
O2 content in the flue gas of max. 8% has been
achieved (on 3LN burners multiflam max. 7% residual
O2 content in the flue gas).
Note If the burner is fitted with an auxiliary motor and

speed control the value selected by the turn knob is
displayed in the last line.
:70.0
FC
Point
1
O2
4.9
:70.0
:15.0
:15.0
:10.0
:19.0
FC
:70.0
Point
: 1
O2
6.4
Load
Burn
Air
FC
Load :15.0
Burn:15.0
23.6
Air :2
Aux1 :19.0
FC
Point
save>ENTER
delete- >ESC
50.2
:5
esc
:15.0
:15.0
:23.6
:50.2
Minimum speed
Fuel
Load
Burn
Air
Aux1
Ch. 9.6.1
Point Load: 10.5

Point I Point
: 1 C
Change?
Point Load:15.0
1 Burn:15.0
O2
Air :10.0
A
4.9 Aux1 :19.0
3. Carry out combustion analysis and if necessary

optimise combustion by adjusting the air damper
position.
5. Leave programming of point 1 by pressing <ESC>.
Point
: 1
O2
4.9
Change load point 1
2. Reduce speed1 (not below minimum speed). To

achieve minimum speed it may be necessary to repeat
steps 1 and 2.
4. Leave point 1 by pressing <ESC> and save by

pressing <ENTER>.
Ch. 9.6.1
GasSettings
CurveParams
Point Load :15.0
P
Burn:15.0
ManualAir :10.0
Aux1 :19.0
FC
At the first load point the fuel dependent minimum speed1

should be aimed for whilst observing the combustion
quality and flame stability.
Ch. 9.6.1
RatioControl
ProgramStop
ProgramStop
Curr: 52 Interv 2
New: deactivated
Setting
FC
Frequency
at transformer
Oil (pump separate)
60 %
approx. 30 Hz
Oil (pump fitted)
70 %
approx 35 Hz
Gas
50 %
approx 25 Hz
only W-FM 200 with speed control

21
6
Drive to full load via intermediate load points
Starting from the first load point, drive to full load via the
intermediate load points.
Procedure:
1. Set cursor to Manual and press <ENTER>.
2. Increase burner rating using the dial knob, whilst
guarding the combustion quality (excess air, flame
stability).
3. Set intermediate point before reaching the combustion
limit by pressing <ENTER> (on 3LN multiflam max. 7%
residual O2 content in the flue gas).
4. Carry out combustion analysis and correct intermediate
load point values.
5. Leave load point by pressing <ESC> and save with
<ENTER>.
Increase load manually

Point Load:15.0
Burn :15.0
Hanual Air :23.6
M
Aux1 :19.0
Ch. 9.6.1
O2
Load :15.0
6.4 Burn :15.0
Manual Air :23.6
. Aux1 :19.0
:15.0
O2
Load:25.0
6.1 Burn :23.8
Manual Air :31.4
:19.8 Aux1 :27.3
Setting intermediate load points, correcting and saving

O2
Load :25.0
6.1 Burn :23.8
Manual Air :31.4
:19.8 Aux1 :27.3
Repeat procedure until full load (Load: 100) has been

reached.
FC
Point
Save- >ENTER
enter->ESC
Point
:5
O2
3.8
22
O2
Load :25.0
L
roint18.7
Punkt Load:25.0
:28.4
: 2uft
2 Burn
:21.9
8O2 Hilfs:60.1
28.8
Air :2
26.0
5.9 Aux1 :2
Load:100
Burn:73.6
Air :67.8
Aux1 :78.5
:56.0
esc
6
6.2.5 Optimising full load
Optimising full load
In the last load point (load = 100%) the exact fuel quantity
throughput for the required full load should be set.
Note Observe load data supplied by the appliance
manufacturer and the capacity graph of the burner.
Procedure:
1. Set fuel throughput
Gas: At 65 to 70 gas butterfly setting, determine
gas throughput and adjust using the setting
screw on the pressure controller.
Oil:
Set pump pressure required, determine oil

throughput and adjust using stepping motor
setting of the oil controller (see burner test data
sheet: Indicator setting oil controller).
2. Determine combustion limit at full load and set excess

air.
The fan speed should be selected as low as possible
whilst observing NOx and flame stability, however it
should not be below 40 Hz / 80% (only when using
frequency converter / W-FM 200).

Point
5
O2
4.5
Load
Burn
Air
Aux1
Point
5
O2
3.8
Load :100
Burn:68.7
76.2
Air :7
78.0
Aux1 :7
FC
:100
68.7
:6
:67.8
:78.5
Ch. 9.6.1
88.8
:8
3. Re-determine fuel quantity throughput and if necessary

adjust.
Once this step has been completed, the pump and gas
setting pressure must not be altered.
4. Save full load point.
23
6
6.2.6 Re-define intermediate load points
Re-define load point 1
To later allow O2 control across the whole ratings range,
point 1 must be a minimum 30% below the required partial
load (only when using an O2 module / W-FM 200).
Procedure:
1. Select point 1 with dial knob, press <ENTER>, confirm
Change point with <ENTER>, point 1 is started.
2. Check combustion quality, and optimise if necessary.
Drive to combustion limit, note down and set excess air
required for combustion limit.
Excess air: without O2 control approx. 15% to 20%
with O2 control approx. 20% to 25%
Drive to load point 1 and optimise combustion

Point
:5
O2
3.8
Load :100
Burn:68.7
Air:76.2
Aux1 :78.2
Point
:1
O2
6.4
Load :15.0
Burn:15.0
Air :23.6
Aux1 :19.0
Point Point
: 1 c
vhange?
lschen?
Point
Load:15.0
11.9
: 1 Burn:1
22.2
O2
Air :2
6.3 Aux: 18.6
Please observe the minimum speed and the mixing

pressure required.
FC
50.0
:5
3. Determine fuel quantity throughput and carry out

ratings distribution.
4. Save load point 1.
Delete intermediate points

Delete intermediate load points and re-define.
To achieve an even speed reference line, the fan speed at
the newly set intermediate load points should not be
altered (only when using a frequency converter / W-FM
200).
Procedure;
Select Point 2 with dial knob, press <ENTER>, confirm
Delete point with <ENTER>, point 2 is deleted and the
setting values for the next intermediate load point
below point 2 appear automatically.
Repeat procedure, until full load settings appear under
point 2.
Do not delete the full load point (Load: 100) and point
1.
Check
Select point 3 with dial knob. If all intermediate load
points have been deleted, no values are defined in
point 3 and the following display is shown.
Point Load :XXXX
: 3 Burn: XXXX
Manual Air :XXXX
Aux1 :XXXX
24
Delete intermediate load points

Point
: 1
O2
6.3
Load:15.0
Burn:11.9
Air :22.2
Aux :18.6
Point
: 2
O2
5.9
Load:19.8
Burn :19.3
Air :25.5
Aux1 :23.2
Point Point
: 2 change?
lelete?
Manual d
49.6
Point Load :4
: 2 Burn: 35.9
Manual Air: 47.3
44.2
47.1 Aux1 :4
Point
:2
O2
3.8
Load: 100
Burn: 68.7
Air :76.2
Aux1 :78.2
6
Set new intermediate load points and carry out ratings
distribution in percentages
For burner operation 5 load points are required, this means
at least 3 intermediate load points must be set.
depending on the installation, more intermediate load
points may be required (maximum 15 load points).
Note When using O2 trim control, partial load cannot be
set below point 2, this means point 2 should be set
smaller or equal to the eventual partial load.
Procedure
1. Leave load point by pressing <ESC>, select manual
function using the dial knob and confirm with
<ENTER>.
Reduce rating and optimise combustion

Ch. 9.6.1
Point Load: 100

Burn :68.7
Hanual Air :76.2
M
Aux1 :78.2
O2
Load :100
3.8 Burn :68.7
Manual Air :76.2
0 Aux1 :78.2
100
O2
3.9
Hand
.
:90.0
2. Whilst observing the combustion quality, reduce the

burner rating using the dial knob.
Recommendation: 10% steps
FC
4. Determine fuel quantity throughput, calculate rating

and carry out ratings distribution.
5. Leave point using <ESC> and save with <ENTER>.
6. Repeat procedure for all curve points.
Point
: 3
O2
4.0
Load
Burn
air
Aux1
:84.2
esc
Point
Save- >ENTER
Delete->ESC
3. Optimise combustion quality and set excess air

required for the combustion limit
Excess air: without O2 control approx. 15% to 20%
with O2 control approx. 20% to 25%
To maintain an even speed reference line, the speed
should not be adjusted after this process if at all
possible (only when using a frequency converter / WFM 200).
Load :90.0
Burn :62.0
Air :69.7
Aux1 :71.2
Point Load :89.7
: 3 Burn: 62.0
O2
Air: 68..8
70.7
4.0 Aux1 :7
:100
:68.7
:76.2
:78.2
esc
P
Point Load
Burn
HAnd Air
Aux1
FC
:89.7
:62.0
:68.8
:70.7
:84.2
Example ratings distribution

Ch. 9.6.1
Throughput intermediate load point
Rating [%] =
100
Throughput full load
Gas:
Rating [%] =
305 m3/h
340 m3/h
100 = 89.7 %
Oil:
Rating [%] =
Point
: 3
O2
4.0
260 kg/h
290 kg/h
.
Load:90.0
Burn:62.0
Air :68.8
Aux1 :70.7
100 = 89.7 %
Punkt
: 3
O2
4.0
Load
Burn
Air
Aux1
89.7
:8
:62.0
:68.8
:70.7
25
6
6.3 O2 functions modulating
The settings for the O2 trim control must only be carried
out if a W-FM 200 with O2 trim control is to be used.
6.3.1 Set O2 guard

The combustion limit has to be determined for each P
point, and saved in the guard function as the O2 minimum
value. The operating type for O2 control / guard or must be
deactivated during setting.
If the O2 limit values are already known, these can be
entered directly as O2 minimum values.
It is also possible to drive to the combustion limit of each
load point and to copy over the determined O2 set points
as O2 min. values.
O2 guard
Direct entry of known O2 limit values:

1. Select point to be set using the dial knob and confirm
with <ENTER>.
Direct entry O2 min value
2. Select O2 min value using dial knob and confirm with

<ENTER>.
3. Enter the O2 min value using the dial knob and save
with <ENTER>.
Ch. 9.7.1
Param + Display
O2Ctlr/Guard
Setting
O2 Guard
Ch. 9.7.1
Point:1
13.9%
:
100%
Point:9
:9
Point:9
100%
02-Minval: 0.0.
P-Airman : 0.0
Point:9
100%
02-Minval: 0..7
P-Airman:
0.0
4. Enter O2 min value in the O2 graph on the right.
2. Select P air manual using dial knob and confirm with

<ENTER>.
3. Turn dial knob to the right. The air rating is reduced on
the curve flow line in relation to the ratings setting of P
air manual. The fuel quantity throughput remains
unchanged.
Reduce air rating until the combustion limit (CO or
soot) has been reached.
4. Leave setting level with <ESC> and save the O2 value
as min value for the guard function using <ENTER>.
5. Enter O2 min value in the graph on the right.
Determine combustion limit

Ch. 9.7.1
Point:1
13.9%
:
100%
Point:9
:9
Point:9
100%
02-Setpoint: 3.8
P-AirHand: 0.0.
Point:9
100%
02-Setpoint: 0.7
10.4 .
P-AirMan:1
O2 graph
8
7
O2 content [%]
Determine O2 value of combustion limit and note it:

1. Select the point to be set using the dial knob and
confirm with <ENTER>.
6
5
4
3
2
1
0
10
20
30
40
50
60
Burner rating [%]
26
70
80
90
100
6.3.2 Set O2 trim control

For subsequent O2 trim settings, a standardisation has to
be carried out at each point.
O2 trim
Procedure:
1. Select point to be set using the dial knob and confirm
with <ENTER>.
Standardisation
2. As soon as the O2 value is stabilised confirm with

<ENTER>.
Note At point 2 and with 100% the time (Tau) between

the air quantity change and its recognition at the O2
sensor is determined. This results in the controller
parameters for subsequent O2 control.
Ch. 9.7.1
Point
:221.1%
O2 RatioCon: 6.0
O2 SetPoint:3.9
StandardVal:11.3
.
Point:2
21.1%
:
02-Verbund
Point:2
21.1%
: :xxxx
02-Sollwert:xxxx
O2 RatioCon: 6.0
Normierert
:xxxx
If the value
is stable
continue with ENTER
3. Turn dial knob to the right. The air rating is reduced on

the curve flow line in relation to the ratings setting of
standardisation value. The fuel quantity throughput
remains unchanged.
The standardised O2 value should be 1 to 1.5% points
above the combustion limit (O2 min value of guard
function) and minimum of 1 % point below the O2 ratio.
4. Leave setting level with <ESC> and save the O2 value
using <ENTER>.
Ch. 9.7.1
Param Display
O2Ctlr/Guard
Setting ...
O2 trim
esc
Point
save- >ENTER
delete->ESC
delay time is
measured O2 Actual
value: 4.2
Measurem success
ControlParam has
been determined
continiue with ESC
Example: O2 set points
Control limit
At burner ratings in the lower load range, the flue gas
velocity at the O2 sensor may not be sufficient for correct
and problem free control. In this case the O2 control limit
must be increased accordingly.
Flue gas velocity [v]: min. = 1 m/s
max. = 10 m/s or sensor temperature
min. 680C
QB L
v=
QB =
L =
=
T =
d =
T+273
273
d2 0.785 3600
8
7
O2 Content [%]
Following completion of the O2 standardisation the ratio

curve points should not be altered, otherwise the
standardisation for the point altered will be deleted and
O2 control will not be possible. If a curve point is altered,
the standardisation for this point will have to be repeated.
O2
6
5
ratio
Con
trol
O2 S
etP
oint
O2 G
uard
4
3
2
1
0
10
20
30
40
50
60
70
80
90
100
Burner load [%]
O2 control limit
Param + Display
O2Ctrl/Guard
Setting ...
O2CtrlThreshold
Ch. 9.7.1
Fuel throughput (kg/h) (m3/h)

Stoichiometric air requirement (m3/kg) (m3/m3)
Air number
Flue gas temperature C
Flue gas pipe diameter (m2)
General formula: v =
QB 0,0046
2
T+273
273
27
6
6.3.3 Set O2 controlling functions
The O2 trim control function is set using OptgMode.
O2 operating mode
man deact
The O2 control and O2 guard are deactivated. The burner
starts with cold sensor (only for commissioning, not
recommended for normal operation).
Param + Display
O2Ctrl/Guard
Setting ...
OptgMode
OptgMode
Curr: man deact
New: conAutoDeac
O2 guard
Only the O2 guard is active.
Start-up only when the operating temperature of the
sensor has been reached.
If the O2 guard reacts, or if an error is detected during
measuring, lockout occurs, if there is no possibility of
repetition.
Ch. 9.7.1
O2 controller
The O2 controller and O2 guard are active.
Start-up only when the operating temperature of the
sensor has been reached.
measuring, lockout occurs, if there is no possibility of
repetition.
conAutoDeact
The O2 controller and O2 guard are active.
Start-up before operating temperature of the sensor has
been reached.
measuring the function auto deact is initiated.
auto deact (not recommended)
The O2 controller and the O2 guard have been deactivated
automatically by the function
conAutoDeact.
The burner remains in operation, however without O2
control and O2 guard.
6.3.4 Check and optimise O2 control
Check O2 control
Procedure:
1. Re-start burner in automatic operation. The start
behaviour can be checked again.
2. Change rating with external signal, so that the O2 value
can be checked on the display of the ABE i.e.
connect a 3 pole switch to X5-03 and change over the
LC operating type to ExtLC X5-03.
3. In menu OperationalStat select NormalOperation
and change over to the second display using
<ENTER>.
4. Carry out various load changes across the whole
ratings range whilst observing the O2 controllers
behaviour.
28
If the O2 sensor has reached its operating temperature,

and the controllers damping time (10 x Tau in partial load)
has elapsed, pre-control starts and the O2 value goes
close to the set point. If within the delay time (approx. 2 x
Tau in full load) no load changes occur, control goes to the
O2 set point. The actual O2 value should then be equal to
the O2 set point.
When a load change occurs the O2 controller is locked at
the existing value, and the air motors are re-adjusted with
the pre-control starting from the previous differential value
setting. This means that the O2 set point is almost
maintained even during pre-control.
Note The O2 control can also be guarded using
recording software.
6
6.3.5 Optimise O2 control
Depending on site specific requirements it may be
necessary to adjust the O2 control parameters in the
SERV level.
O2 control parameters
Param + Display
O2Ctlr/Guard
Setting ...
ControllerParams
Ch. 9.7.1
O2 actual value fluctuates

If the control fluctuates parameter I and P should be
optimised.
In the lower ratings range:
I-Partial reduce
increase
or
PP-Partial load
reduce
In the upper ratings range
I-Full load load
increase
or
P-Volllast
P-Full load
O2 control remains locked
If a ratings change occurs prior to the end of the locking
times the controller remains stationary.
LoadCtrlSuspend
FilterTmeLoad
increase
reduce
O2 guard reacts at ratings change

A rapid ratings change will result in lockout by the O2
guard.
LoadCtrlSuspend
O2Offset
increase
increase
29
6
6.4 Concluding work following commissioning
6.4.1 Lower load limit (partial load)
Observing the instructions given in the installation and
operating instructions of the burner and the instructions
given by the appliance manufacturer, partial load and the
control range should be set in menu Load limits. Here,
partial load is defined with parameter MinLoad.
Set lower load limit
Flue gas temperature limit value

If the limit value is exceeded the warning Flue gas
temperature too high is given. A prerequisite for this is a
configured flue gas temperature sensor on the O2 module
(only W-FM 200).
The limit value should be set approx. 20% above the flue
gas temperature at nominal load.
Set flue gas temperature limit values
Ch. 9.6.1
GasSettings
LoadLimits
MinLoadGas
MinLoadGas
Curr: 0.0%
22.8%
New:
Ch. 9.12.1
Param + Display
O2 Module
Configuration
MaxTempFlueGas
Overheating due to flue gas temperatures

above 300C can damage the O2 sensor.
ATTENTION
Select second fuel (only on dual fuel burners)

Select required fuel using the external fuel selection
switch. If an external selection switch is not available fuel
selection is made with the ABE or BMS.
Note The external fuel selection switch has priority, this
means commissioning can only be carried out with
the fuel selected with this switch.
30
Fuel Selection
Operation
Fuel
Curr fuel
Fuel selection
Curr: Oil
New: Gas
Ch. 9.3
or:
Fuel selection
switch set
to oil
6
6.4.2 Concluding work on the burner
Following commissioning the following, concluding work
has to be carried out on the burner.
Set air pressure switch.
Set gas and oil pressure switches.
Remove measuring devices,
etc ...
More detailed information can be obtained from the
installation and operating instruction of the burner.
31
Commissioning multi-stage
Prior to commissioning the preparations necessary for

commissioning (Ch. 5) must be completed.
7.1 Set fuel and required load

Burner OFF
To be able to carry out the following steps the burner has
to be set to OFF in menu Manual Operation.
Burner OFF
Select fuel Oil (only on dual fuel burners)

Select fuel Oil using the external fuel selection switch. If an
external fuel selection switch is not available, fuel is
selected using the ABE or BMS.
Select fuel
Note The external fuel selection switch has priority, this

means commissioning can only be carried out with
the fuel selected with this switch.
Select required rating S1

In menu Manual operation call up the function required
load and set to S1.
32
Ch. 9.4
Manual operation
Auto/Manual/Off
Auto/manual/Off
Curr: Automatic
New:: Burner Off
Operation
Fuel
Curr fuel
Fuel selection
Curr: Gas
New: Oil
Ch. 9.3
or:
Fuel selection
switch is set
to Oil
Select fuel
Manual operation
Required load
Required load
Curr: S3
New: S1
Ch. 9.3
7
7.2 Adjust burner
7.2.1 Preset curve parameter
For commissioning the fan speed1 and air damper setting
of each operating point as well as the On/Off switch points
must be checked and if necessary adjusted.
Procedure;
1. Call up stepping motor positions.
2. Select option Without start
3. Call up operating, the on and off stage switch points
one by one using the dial knob and compare air damper
setting (air stepping motor) and fan speed1 (FC) with
table values. If they deviate, overwrite the parameter
by
calling up operating, on and off switch points with
<ENTER>,
selecting parameter using dial knob and confirming
with <ENTER>,
inputting parameter value (dial knob +/-) and saving
with <ENTER>.
Continue procedure until all parameters are the same
as the table values.
Call up stepping motor positions

Ch. 9.6.1
Param + Display
RatioControl
Oil Settings
CurveParams
Curve Settings
Stepping motor
positions
With start
Without start
Activate option without start

Ch. 9.6.1
Point Air :40.0
::BS1 FC
:80.0
O2
xxxx
Stepping motor
positions
With start
W
Without
start
Call up operating, on and off switch points

two
operating stages
Air damper [<]

Air
Speed [%]
PC
Operating point BS1

Switch on point ES2
40
80
Switch off point AS2

Operating point BS2
70
100
three
operating stages
Point Air
::BS1 FC
O2
xxxx
Ch. 9.6.1
Point Air :40.0
ES2 FC
::E
:90.0
O2
xxxx
:40.0
:80.0
Overwrite parameters
Air damper [<]
Speed [%]1
Air motor
Auxiliary motor
Operating point BS1

Switch on point ES2
Operating point BS2
Switch on point ES2
Operating point BS3
30
80
50
90
70
100
4. Exit level with <ESC>.
Point Air :40.0

ES2 Point
::E
FU ALir
ir0 :40.0
:ES2 FC
:90.0
O2
xxxx
change values with dial knob
Point Air
:ES2 FFC
O2
xxxx
:40.0
:90.0
Point Air
:ES2 FFC
O2
xxxx
:40.0
:80.0
Point Air
:ES2 FC
O2
xxxx
:40.0
80.0
:8
save values
Exit level
Without start
Operating point S3
Air motor: 70.0

AAux motor: 100
esc
SSpecialPositions
CurveParams
LoadLimits
Only W-FM200 in connection with frequency

converter
33
7
Set programme stop 36
Prior to first ignition the programme stop has to be set to
36 IgnitionPos. After burner start, the burner then drives to
ignition position without igniting (with long pre-ignition,
ignition is carried out without fuel release).
Note In its delivered condition the programme stop has
already been factory pre-set to 36.
Open manual fuel isolation devices and start burner

Once the fuel shut off devices have been opened the
burner should be started in manual operation.
Note For the burner start all safety devices, pressure and
temperature controllers must be in operating
position.
Sufficient heat demand must be ensured for the
duration of commissioning.
Programme stop 36: Ignition position without ignition

Ch. 9.6.1
SpecialPositions
ProgramStop
ProgramStop
New: 36 IgnitionPos
Burner On
Ch. 9.4
RatioControl
Auto/Manual/Off
Auto/Manual/Off
Curr: Burner Off
New: Burner On
Setting ignition position

The fan speed and the ignition position of the air damper
should be set whilst observing the mixing pressure. The
ignition speed1 should not be below 80%. Depending on
the burner, the mixing pressure for ignition should be
between 3 and 5 mbar. The mixing pressure can be
adjusted with the air damper and diffuser positions.
It is recommended to note down the IgnitionPos set
values..
Set air damper fan speed and ignition position
Set programme stop 44

To be able to ignite the burner the programme stop has to
be set from 36 to 44. Once the pre-ignition time has
elapsed fuel is released. The stepping motors remain in the
ignition position setting.
Programme stop 44: ignition position after safety time
RatioControl
OIlSettings
SpecialPositions
IgnitionPos
IgnitionPosOil*
IgnitionPosAir
IgnitionPosAux
IgnitionPosFC
SpecialPositions
ProgramStop
Programmstopp
New: 44 Interv 1
Ch. 9.6.1
* The IgnitionPosOil does

not need to be set for
multi-stage operation, as
no oil throughput regulator valve and thus no
stepping motor is fitted.
Ch. 9.6.1
Check fuel pressure

The atomising pump pressure is factory pre-set and can be
determined from the burner test data sheet.
Deactivate programme stop
The programme stop has to be deactivated to continue
commissioning. If the programme stop is not deactivated,
the burner remains in the existing position, the setting of
new load points is therefore not possible.
34

converter
Deactivate programme stop

ProgramStop
Curr: 44 Interv 1
New: deactivated
Ch. 9.6.1
7
Activate option With start
In stepping motor positions activate the option With start
by pressing <ENTER>.
Note Operation of the switch off points should be
avoided during commissioning, as this can lead to
excessive air deficiency.
Pre-set operating point S1

1. Select operating point S1 using the dial knob and
2. Call up parameter values using the dial knob and
<ENTER> and adjust operating point BS1 whilst
observing the combustion quality.
Activate option With start

CurveParams
Curve Settings
Stepping motor
positions
With start
Without start
Ch. 9.6.1
Point Air
::BS1 FC
O2
xxxx
:40.0
:80.0
Pre-set operating point and set switch on point

Point Air
::BS1 FC
O2
xxxx
:40.0
:80.0
Lir
Point A
:BS1 F C
O2
xxxx
:36.0
:80.0
Ch. 9.6.1
Note The burner motor speed XX should not be selected

below 70% (30 Hz).
3. Exit parametering with <ESC>.
Set switch on point S2

1. Select switch on point S2 using the dial knob and
2. Call up parameter values using the dial knob and
<ENTER> and increase excess air whilst observing the
flame stability.
3. Note down values.
Point Air
:BS1 FC
O2
xxxx
36.0
:3
74.0
:7
esc
Point Air
::BS1 FC
O2
xxxx
:33.0
:63.0
Start next operating or

switch on point and set
parameter.
Do not operate switch off
point
Note When using a three stage burner the procedure has

to be repeated for operating point BS2 and switch
on point ES3.
Set Full Load

1. Select full load point using the dial knob and confirm
with <ENTER> .
2-stage burner:
operating point BS2
3-stage burner:
operating point BS3
2. Determine fuel throuhput and adjust if necessary.
3. Call up the parameter values using the dial knob and
<ENTER> , and optimise combustion (carry out a
combustion test)
4. After saving with <ENTER> exit parametering with
<ESC> .

converter
35
7
7.2.4 Set switch off point(s)
Change over to option Without start
Exit option With start in stepping motor positions with
<ESC> and re-enter Curve setting to select option
Without start and activate with <ENTER>.
Activate option Without start
Set switch off point S2

1. Using the dial knob select switch off point AS2 and
2. The air damper and motor speed of switch on point of
ES2 should also be set for the switch off point of AS2.
and save with <ENTER>.
Set switch off point(s)
Note When using three stage burners repeat procedure

and transfer values from switch on point ES3 to
switch off point AS3.
Curve Settings
Stepping motor
positions
With start
W
Without
start
Point Air
AS2 FC
::A
O2
xxxx
:50.0
:90.0
iir
Point A
:AS2 F C
O2
xxxx
:50.0
:90.0
Ch. 9.6.1
Point Air :33.0
::BS1 FC
:63.0
O2
xxxx
Ch. 9.6.1
Point Air
:AS2 FC
O2
xxxx
42.0
:4
69.0
:6
esc
Point Air
::AS2 FC
O2
xxxx
:42.0
:69.0
On three stage burners:

Call up switch off point AS3
and transfer the values
from switch on point ES3.
7.2.5 Check operation of, on and off switch points

If the pump pressure has been changed during full load
adjustment the operating and switchover points has to be
checked.
Carry out combustion check

activate option With start.
Drive to operating point BS1 and check combustion

quality.
If necessary, optimise combustion quality by changing

the air damper setting and burner motor speed.
During this procedure, the pump pressure must not be
altered.
Check on and off switch points

Drive to operating points several times, whilst checking the
on and off switching behaviour of the second or third
stages and optimise if necessary.
36
Note With 3-stage operation an additional combustion

quality check for stage 2 (operating point BS2) is
required.
7
7.2.6 Check start behaviour
Procedure:
1. Set ProgramStop to phase 44.
2. Re-start burner in manual operation.
3. Check start behaviour and if necessary correct ignition
load setting.
Programme stop
SpecialPositions
ProgramStop
ProgramStop
Curr: deactivated
New: 44 Interv 1
Ch. 9.6.1
Note If the ignition load setting has been altered, the start
behaviour has to be rechecked.
4. Deactivate programme stop.
Restart burner
Auto/Maual/Off
Auto/Manual/Off
Curr: Burner Off
New: Burner Off
Auto/Manual/Off
Curr: Burner On
New: Burner On
Ch. 9.4
7.2.7 Define full load as required load

Call up function required load in menu Manual operation
and set to full load.
two stage operation: BS2
three stage operation: BS3
Set required load

Manual operation
Required load
Required load
Curr: BS1
New: BS3
Ch. 9.4
37
Load controller
The controller has to be configured relevant to the

installation to ensure safe and reliable load control. On the
W-FM100 the load controller is optional.
8.1 Set operating mode

The operating mode determines if and how the internal
load controller is used and if an external load controller is
connected.
If the internal load controller is deactivated in menu
SystemConfig, it can only be reactivated in this menu.
Note As an emergency function switchover from the
external load controller to the Int LC can be carried
out with a switch contact on input X62. The Int LC
must be configured for this and must be equipped
with a process condition (temperature/pressure)
sensor.
ExtLC X5-033 point step input signal of external load
controller to X5-03
.
Int LC
Internal load controller with 2 set points.
Int LC Bus
Digital set point signal from building

management system via eBus or Modbus.
The ABE acts as interface.
Int LC X62
Analogue set point signal from the

building management system on input
X62
(4 to 20 mA or 0 to 10V).
switchover to the internal set point W1 is
possible with an external switch contact
on terminal X62:1/2.
Ext LC X62
Analogue setting signal from the building

management system on input X62 (4 to
20 mA or 0 to 10V).
Ext LC Bus
Load control is carried out by the building

management system.
Signal transfer is carried out with eBus or
Modbus, the ABE acts as interface.
38
Set operating mode

Param + Display
LoadController
Configuration
LC-OptgMode
LC-OptgMode
Curr: Int LC
New: Int LC
Ch. 9.8.4
8
8.2 Configure sensors
Sensors used
Sensor selection has to be configured depending on
whether the actual value is determined by a temperature
sensor (input X60) or a temperature or pressure sensor
(input X61).
PT 100
PT 100 sensor on terminal X60:1/2/4,

temperature limit (TL) function is active.
PT 1000
PT 1000 sensor on terminal X60:3/4,

Ni 1000
Ni 1000 sensor on terminal X60:3/4,

PT100 PT1000
PT 100 sensor on terminal X60:1/2/4

for temperature controller function.
PT 1000 sensor on terminal X60:3/4
for temperature limit (TL) function.
Configure sensors
Param + Display
LoadController
Configuration
Sensor selection
Sensor selection
Curr: PT 100
New: PT 100
Ch. 9.8.4
PT 100 Ni 1000 PT 100 sensor on terminal X60:1/2/4

for temperature controller function.
Ni 1000 sensor on terminal X60:3/4 for
temperature limit (TL) function.
TempSensor
Temperature sensor on input X61, no
(thermocouple) temperature limit (TL) function.
PressureSens
Pressure sensor on input X61, no limit

(TL) function.
None
No sensor fitted to W-FM.
Sensor measuring range

To allow correct actual value determination the measuring
range of the sensor has to be defined.
MeasR PtNi
: 150C/302F or 400C/752F
MeasR TempSensor : 0 to 2000C

MeasR PressSens : 0 to 99.9 bar
Set measuring range

Param + Display
LoadController
Configuration
MeasureRange PtNi
MRange TempSens
MRange PressSens
Ch. 9.8.4
MeasureRange
Curr: 150C/302F
New: 400C/752C
The measuring range is also the setting range for the

external set point.
Sensor signal
If the actual value is determined by a sensors connection
to input X61, the relevant analogue signal has to be set.
4 to 20 mA : Current signal on terminal X61:3
with load limit (TL)
2 to 10 V
: Voltage signal on terminal X61:2

with load limit (TL)
0 to 10 V
: Voltage signal on terminal X61:2

without load limit.
Set analogue signal at input X61

Param + Display
LoadController
Configuration
Ext Inp X61 U/I
Ext Inp X61 U/I
Curr: 0 ... 10 V
New: 4 ... 20 mA
Ch 9.8.4
39
8
8.3 Set point (external)
External load / set point signal
If a load controller is connected to input X62 (Ext LC X62),
or if the set point signal for the internal load controller (Int
LC X62) is given by this input, the type of analogue signal
must be defined.
Ext LC X62 (load signal)
: 4 to 20 mA or 2 to 10 V
Int LC X62 (set point signal)
: 4 to 20 mA or o to 10 V
Set limit values for external set point

The set point signal for the internal load controller (Int LC
X62) can be limited in parameter Ext MinSetPoint and Ext
MaxSetPoint.
The percentages given for the limit relate to the value set
under MeasureRange PtNi.
Example:
Upper set point limit required = 80C
MeasureRange PtNi = 150C
Calculation
80C
150C
40
100 53,3%
Define analogue signal at input X62

Param + Display
LoadController
Configuration
Ext Inp X62 U/I
Ext Inp X62 U/I
Curr: 4 ... 20 mA
New: 0 ... 10V
Ch. 9.8.4
Set limit values

Param + Display
LoadController
Configuration
Ext MinSetPoint
Ext MinSetPoint
Curr: 0%
New: 33%
Ch. 9.8.4
Ext MaxSetPoint
Ext MaxSetPoint
Curr: 100%
New 5 3%
8
8.4 Set point (internal)
Internal set points (W1 / W2)
Two internal set points can be stipulated.
Switchover is with potential free contact on the terminals
X62:1/2.
The set points cannot be set above the temperature limit
value already entered.
Internal set points (W1 / W2)
Switching differential
The on and off switch point is given in percent relating to
the set point.
Switch differential
Set point70C
Sd_ModOff
Sd_ModOn-
10%
5%
Installation Off
Installation On
70C + 7.0K = 77.0C

70C - 3.5K = 66.5C
(from 70C = + 7.0K)

(from 70C = - 3.5K)
Param + Display
LoadController
ControlParam
ContParamList
Setpoint W1
Setpoint W2
Setpoint W1
Curr: 80C
New: 70C
Param + Display
LoadController
ControlParam
Sd_ModOn
Sd_ModOff
Ch. 9.8.1
Ch. 9.8.1
Sd_ModOn
Curr: 3%
New: - 5%
Note If a positive Sd_ModOn is defined, the switch on

point will be above the set point.
Temperature limit (TL)

If the temperature limit is exceeded, the installation
switches off and the message internal
temperature limit (TL_ThreshOff) has reacted is displayed.
The switch on threshold is given in percent relative to the
set point temperature.
If a thermocouple or pressure sensor has been configured,
the limit function is inactive.
TL Threshold Off
TL SwDiff On
Temperature limit
Param + Display
LC-OptgMode
TempLimiter
TL_ThreshOff
TL_SD On
Ch. 9.8.2
TL_ThreshOff
Curr: 95
New: 90
90C
- 10% (from 80C = 9.0K)
Installation Off
90C
Switch on threshold 90C - 9.0K = 81C
41
8
8.5 Modulating load control
8.5.1 Parametering internal load control
Adaption
During adaption, the internal load controller recognises the
control section and calculates the PID parameter.
Adaption can be started in manual or automatic operation
independent of the operating phase (standby or
operation).
During adaption, the parameter SW-FilterTmeCon should
be between 2 and 4 seconds. If the value selected is too
high, this can stop the adaption or lead to insufficient
control parameters.
Filter time
Adaption rating
If during adaption insufficient heat demand is available, full
load can be limited to up to 40% in parameter
AdaptionLoad.
However, if the AdaptionLoad selected is too low, this can
stop the adaption.
Adaption Load
Start adaption
Select parameter StartAdaption and confirm with
<ENTER>. The respective phases of adaption are
displayed alternately with the actual value and load signal.
Start adaption
Phases of adaption:
Decreasing of temperature (Temp decrease)
Before the adaption can be started, the actual
temperature (or pressure) must be 5% below the set
point temperature (or steam pressure).
Determine actual value (stabilising phase)

The direction of the actual value is determined for 5 min.
During this time the actual value should be constant.
If strong fluctuations occur the time is increased to
maximum 10 min, and anything greater leads to
termination.
Start-up (heating)
The direction of the actual value during the heat up
phase is determined.
calculation of control parameter (Adaption ok)

Using the measured values of the stabilising phase,
the heat input and reaction times and the PID
parameter are calculated.
The values calculated can be called up using the dial
knob.
Standard control parameters

If an adaption is not possible or not necessary, standard
parameters can be used as PID values. Various settings
are available depending on the behaviour of the control
section.
very slow
slow
normal
fast
very fast
42
P (Xp)
30 %
15 %
7%
4%
40 %
I (Tn)
400 s
320 s
90 s
35 s
55 s
D (Tv)
10 s
40 s
50 s
17 s
15 s
Param + Display
LC-OptgMode
Regelparameter
SW-FilterTmeCon
SW-FilterTmeCon
Curr: 3 s
New: 3 s
Param + Display
LC-OptgMode
Adaption
AdaptionLoad
AdaptionLoad
Curr: 100%
New: 80%
Param + Display
LC-OptgMode
Adaption
Start adaption
Ch. 9.8.1
Ch. 9.8.5
Ch. 9.8.5
Start adaption
with ENTER
12
Set point
80C
Actual value 79C
Adaption complete
Adaption ok
P-content (Xp)
11.2%
continue with <>
Adaption ok
P-content (Tu)
53s
continue with <>
Standard control parameters

Param + Display
LC-OptgMode
ControllerParam
ContrlParamList
StandardParam
SW-FilterTmeCon
Curr: XXX
New: Normal
Ch. 9.8.1
8
8.5.2 Optimising internal load control
Control behaviour
Observe load control for some time during operation and if
necessary optimise the PID parameter.
Adapt PID parameters
Setting adjustment stability

With the MinActuatorStep unnecessary drive impulses of
the stepping motors can be reduced and thus their
longevity increased.
However, the MinActuatorStep adjustment affects the
precision control and stability of the load control.
Setting adjustment stability
Erroneous signal filter

Using a filter with time constants (SW_FilterTmeCon),
signals which affect the D-Part can be weakened.
However, a time filter that is too long will have a negative
effect on the control.
Fault signal Filter
Recommendation: 2 to 4 seconds
Param + Display
LC-OptgMode
ControllerParam
ControlParamList
P-Part (Xp)
I-Part (Tn)
D-Part (Tv)
Param + Display
LC-OptgMode
ControllerParam
MinActuatorStep
MinActuatorStep
Curr: 1.0%
New:
2.0%
Param + Display
LC-OptgMode
ControllerParam
SW_FilterTmeCon
SW_FilterTmeCon
Curr: 3 s
New: 4 s
Ch. 9.8.1
Ch. 9.8.1
Ch. 9.8.1
43
8
8.6 Multi-stage load control
Switching differentials
The switching differentials are formed in percentages
depending on the current set point.
SD_S
Stage1On:
At this switching differential the control circuit is closed
and the burner is switched on.
SD_S
Stage1Off:
As this switching differential is exceeded the control circuit
is opened and the burner is switched off.
Switching differentials
Param + Display
LC-OptgMode
ControllerParam
SD_Stage1On
SD_Stage1Off
SD_Stage2Off
SD_Stage3Off
Ch. 9.8.1
SD_Stage1On
Curr: 1.0%
New: 1.0%
SD_S
Stage2Off:
As this switching differential is exceeded the system is
switched from stage 2 to stage 1.
SD_S
Stage3Off:
As this switching differential is exceeded the system is
switched from stage 3 to stage 2.
Switch thresholds
This is the integral (I) from the control devitation multiplied
by the time.
This function monitors the behaviour of the installation.
depending upon demand the next higher load stage is
selected.
The control devitation refers to the set point (W1 or W2).
ThresholdStage2On:
Switch criteria for the release of second stage.
ThresholdStage3On:
Switch criteria for the release of third stage.
Notes for 2 stage operation

If a burner with 3 nozzles is only to be operated in two
stage mode, the ThresholdStage2On should be set to 0.
This means that with the release of the load control the
second nozzle is immediately switched on. The burner is
then in partial load. To ensure correct switch off behaviour,
SD_Stage2Off and SD_Stage1Off should be set to the
same value.
44
Switch thresholds
Param + Display
LC-OptgMode
ControllerParam
ThresholdStage2On
ThresholdStage3On
Ch. 9.8.1
ThresholdStage2On
Curr: 300
New: 300
8
8.7 Cold start function
Activate cold start function
In order to avoid the appliance operating at its maximum
loading before the required minimum appliance
temperature or pressure has been reached, the cold start
function has to be activated.
Activate cold start function
Additional sensor
A separate temperature sensor (terminal X60) for the cold
start function must only be activated if either a temperature
or pressure sensor on terminal X61 is used for the load
control.
The switch thresholds then relate to the set point for the
additional sensor.
Configure additional sensor
Switch thresholds
The thresholds relate to the current set point (W1/W2) or
if an additional sensor is fitted to the Set point add sens.
Switch thresholds
ThresholdOn:
If the actual temperature falls below the switch on
threshold the burner starts in the cold start function.
Param + Display
LC-OptgMode
LC OptgMode
StageSetp_Mod
StageSetp_Mod (stage set point modulating):
If the actual temperature exceeds the next stage set point ,
the cold start load increases by the value set under
StageLoad.
StageSetp_Stage: (stage set point multi-stage):
If the actual temperature exceeds the next stage set point ,
the next stage is released
Time controlled load increase

If the actual temperature does not reach the
StageSetPoint ..., the cold start load (StageLoad) is
increased following the MaxTmeStage...
Cold start On
Curr: deactivated
New: activate
Ch. 9.8.3
Param + Display
LC-OptgMode
ColdStartOn
Additional
Set point add sens
Additional sensor
Set point add sens
Curr: deactivated
Curr: 60C
New: Pt 1000
New: 70C
Param + Display
LC -OptgMode
ColdStartOn
ThresholdOn
ThresholdOff
ThresholdOff:
If the actual temperature exceeds the switch off threshold
the cold start function is deactivated. Set switch
thresholds
Load steps (only with modulating operation)
At parameter, StageLoad the load increase can be set up
to that of the ThresholdOff value.
Ch. 9.8.3
Ch. 9.8.3
ThresholdOn
Curr: 20%
New: 25%
Set StageLoad
Param + Display
LC-OptgMode
ColdStartOn
StageLoad
Ch. 9.8.3
StageLoad
Curr: 15%
New: 15%
Setting StageSetp_Stage
Param + Display
LC-OptgMode
ColdStartOn
StageSetp Mod
StageSetp Stage
Ch. 9.8.3
StageSetp Mod
Curr: 5%
New: 5%
Setting StageSetp_Stage
Param + Display
LC OptgMode
ColdStartOn
MaxTmeMod
MaxTmeStage
Ch. 9.8.3
MaxTmeMod
Curr: 3 min
New: 3 min
45
Parameters and functions
9.1 Menu structure (ABE)

Menu level 1
Menu level 2
OperationalStat
esc
Operation
Menu level 3
Menu level 4
Menu level 5
NornalOperation
Status/Reset
FaultHistory
LockoutHistory
Alarm Act/deact
Boiler setpoint
esc
esc
Setpoint W1
Setpoint W2
esc
CurrentFuel
FuelSelect
Fuel
DisplayClock
Date/TimeOfDay
esc
esc
SetClock
esc
HoursRun
esc
StartCounter
esc
Fuel meter
esc
Date
TimeOfDay
Weekday
Date
TimeOfDay
Weekday
GasFiring
OilStage1/Mod
OiStage2
OilStage3
TotalHoursreset
TotalHours
SystemOnPower
GasStartCount
OilStartCount
TotalStartCountR
TotalstartCount
Curr Flow Rate

Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset Date Gas
Reset Date Oil
LockoutCounter
O2 Module
only W-FM200
esc
Current O2 value
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency
BurnerID
OptgModeSelect
esc
InterfacePC
GatewayBASon
GatewayBASoff
Type of Gateway
O2Ctr Activate
only W-FM200
ManualOperation
esc
SetLoad
Auto/Manual/Off
End user: Access without password

Engineer: Access with SERV password
46
9
Menu level 1
Menu level 2
Param & Display
Menu level 3
BurnerControl
esc
esc
Times
Menu level 4
esc
Times Startup1
TimesStartup2
TimesShutdown
TimesGeneral
Configuration
esc
ProductID
esc
Configuration
General
Menu level 5
esc
esc
esc
FanRunup Tme
Prepurge TmeGas
Prepurge TmeOil
Interval1Gas
Interval1Oil
Interval2Gas
Interval2Oil
MaxTmeLowFire
Postpurge3Gas
Postpurge3Oil
esc
AlarmDelay
DelayStartPrev
esc
AlarmStartprev
ForcedIntermit
ConfigFlameSens
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW version
RatioControl
esc
GasSettings
esc
SpecialPositions
esc
HomePos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetignitPos
CurveParams
LoadLimits
OilSettings
esc
SpecialPositions
CurveParams
LoadLimits
esc
esc
esc
esc
MinLoadGas
MaxLoadGas
HomePos
PrepurgePos
IgnitionPos
PostpurgePos
ProgramStop
ResetignitPos
Curve Settings
MinLoadOil
MaxLoadOil
Auto/Manual/Off
Times
esc
OperatRampMod
OperatRampStage
DriveRamp
ShutdownBehav
ProgramStop

47
9
Menu level 1
Param & Display
Menu level 2
esc
O2Contr/Guard
(only W-FM 200)
Menu level 3
esc
GasSettings
Menu level 4
esc
Menu level 5
OptgMode
O2 Control
O2 guard
Control Param
esc
P Low-Fire
I Low-Fire
Tau Low-Fire
P High-Fire
I High-Fire
Tau High-Fire
O2CtrlThreshold
Type of fuel
esc
Fuel user-def
Control param
esc
esc
V_Lnmin
V_afNmin
V_atrNmin
A2
B / 1000
like theory
like P air
OptgMode
O2 Control
O2 Guard
esc
OilSettings
esc
OptgMode
O2 Control
O2 Guard
Control param
esc
P Low-Fire
I Low-Fire
Tau Low-Fire
P High-Fire
I High-Fire
Tau High-Fire
O2CtrlThreshold
Type of fuel
esc
Fuel user-def
Control param
esc
esc
V_Lnmin
V_afNmin
V_atrNmin
A2
B / 1000
like theory
like P air
O2 OffsetOil
LoadCtrlSuspend
Filter TimeLoad
Process Data
esc
CombEfficiency
ManVar O2 Ctrl
State O2 Ctrl
Air-related Load
Diag Reg State

48
9
Menu level 1
Param & Display
Menu level 2
esc
LoadController
(optional on W-FM
100)
Menu level 3
Menu level 4
ControllerParam
esc
Menu level 5
ContrlParamList
esc
esc
StandardParam
P-Part (Xp)
I- Part (Tn)
D-Part (Tv)
MinActuatorStep
SW_FilterTmeCon
SetpointW1
SetpointW2
SD_ModOn
SD_ModOff
SD_Stage1On
SD_Stage1Off
SD_Stage2Off
SD_Stage3Off
ThreshStage2On
ThreshStage3On
TempLimiter
ColdStart
esc
esc
Configuration
esc
Adaption
esc
TL_ThreshOff
TL_SD_On
ColdStartOn
ThresholdOn
StageLoad
StageSetp_Mod
StageSetp_Stage
MaxTmeMod
MaxTmeStage
ThresholdOff
AdditionalSens
Setp AddSensor
Release Stages
LC_OptgMode
Sensor Select
MeasureRangePtNi
Ext Inp X61 U/I
MRange TempSens
MRange PressSens
Ext Inp X62 U/I
Ext MinSetpoint
Ext MaxSetpoint
StartAdaption
AdaptionLoad
SW version

49
9
Menu level 1
Param & Display
Menu level 2
esc
AZL(ABE)
Menu level 3
Menu level 4
Times
esc
esc
Sum/WinterTime
Time EU/US
esc
UnitTemperature
UnitPressure
esc
Address
SendCycleBU
Menu level 5
Language
DateFormat
PhysicalUnits
eBus
ModBus
esc
Address
Baudrate
Parity
Timeout
Local/Remote
Remote Mode
W3
Display Contrast
ProductID
esc
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version

50
9
Menu level 1
Menu level 2
Menu level 3
Actuators
Param & Display
esc
esc
Addressing
DirectionRot
Menu level 4
esc
esc
ProductID
Menu level 5
1 AirActuator
2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3
Delete curves
1 Air Actuator
esc
esc
2 Gas Actuator
(Oil)
esc
3 Oil Actuator
esc
4 Auxiliary Actuator
esc
5 Auxiliary
Actuator 2
(only on W-FM 200)
5 Auxiliary
Actuator 3
(only on W-FM 200)
SW Version
esc
esc
esc
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
1 AirActuator
2 GasActuat(Oil)
3 OilActuator
4 AuxActuator
5 AuxActuator2
6 AuxActuator3

51
9
Menu level 1
Param & Display
Menu level 2
esc
FC Module
(VSD Module)
(optional on
W-FM 100)
Menu level 3
esc
Configuration
Menu level 4
esc
Speed
Fuel meter
Process Data
esc
ProductID
esc
Menu level 5
esc
esc
Num Puls per R

Standardisation
StandardisedSp
Setpoint Output
PulseValueGas
PulseValueOil
Max Stat Dev

Max Dyn Dev
Num Dev >0.3%
Num Dev >0.5%
Absolute Speed
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
esc
O2 module
(only W-FM 200)
esc
Configuration
esc
Displayed Values
esc
ProductID
esc
O2 Sensor
SupAirTempSens
FlueGasTempSens
MaxTempFlGasGas
MaxTempFlGasOil
Current O2 Value
O2 Setpoint
SupplyAirTemp
FlueGasTemp
CombEfficiency
QGO SensorTemp
QGO HeatingLoad
QGO Resistance
ASN
ProductionDate
SerialNumber
ParamSet Code
ParamSet Vers
SW Version
SystemConfig
esc
LC_OptgMode
Inp3Config..I/U
TempLimiter
esc
TL_Thresh_Off
TL_SD_On
Sensor Select
MeasureRangePtNi
O2Ctrl/LimitrGas
O2Ctrl/LimitrOil

52
9
Menu level 1
Menu level 2
Menu level 3
HoursRun
Param & Display
esc
esc
Menu level 4
GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
TotalHours
SystemOnPower
Reset
esc
StartCounter
esc
esc
esc
ParamBackup
Updating
esc
GasFiring
OilStage1/Mod
OilStage2
OilStage3
TotalHoursReset
GasStartCount
OilStartCount
TotalStartCountR
TotalStartCount
Reset
Fuel Meter
Menu level 5
GasStartCount
OilStartCount
TotalStartCountR
Curr Flow Rate

Volume Gas
Volume Oil
Volume Gas R
Volume Oil R
Reset DateGas
Reset DateOil
BackupInfo
esc
esc
Date
TimeOfDay
BU included?
AZL(ABE) included?
LC included?
ACT1 included?
ACT2 included?
ACT3 included?
ACT4 included?
ACT5 included?
ACT6 included?
VSD included?
O2 included?
LMV5 -> AZL

AZL
-> LMV5
PW Login
PW Logout
Load_SW_from_PC
SafetyCheckFunct
esc
LossFlameTest
SLT Test

53
9
9.2 Operating display
The operating display is accessible by pressing the Info
button, by pressing ESC you return to the previous menu.
NormalOperation
FaultHistory
Display of:
Phases during start up
Set points and actual values
Current burner rating
Flame signal
by pressing ENTER the stepping motor positions,
speed and the O2 value can be displayed.
Fault memory with the last 21 faults.

Display of:
Fuel at onset of fault
Fault group
Fault and diagnostic codes (C/D) see Ch. 12
Phase, in which the fault occurred
Load position and start No.
Status/Reset
LockoutHistroy
If a lockout is present at display NormalOperation, this

can only be reset using parameter Status/Reset.
The display alternates between displaying fault information
and clear text description of the fault. The display is exited
using ESC and the plant can be reset by pressing ENTER.
Memory of the last 9 faults, which caused lockout.

Display of:
Date and time when lockout occurred
Fault and diagnostic codes (C/D) see Ch. 12
Phase, in which lockout occurred (P)
Load position and fuel
Alarm act/deact
With this function the lockout signal output on terminal
X3-)1:2 can be reactivated or deactivated. Deactivation
of the output remains active until reset, the next start or a
system reset.
9.3 Operation
BoilerSetpoint
Switchover from set point W1 to W2 is carried out with

potential free contact at input X62:1/2
Set point switchover W1/W2
X62
Two set points (W1/W2) can be entered for the internal

load controller. The set points cannot be set using the
current guarding temperature (optional on W-FM 100).
Activation
2nd set point
W2
Fuel
Fuel selection with ABE or eBus (BMS) have equal

preference, this means the option selected last is valid.
Date/TimeOfDay
In this menu the date, time and weekday are shown and
can be adjusted if required.
54
2
1
012
If an external fuel selection switch has been fitted, this has

priority.
If an external fuel selection switch is not fitted, or if this
switch has been set to W-FM internal the current fuel can
be changed with the ABE using FuelSelect.
External fuel selection switch
X4-01
Fuel determination with CurrentFuel (read only)
Pre-selection
Oil
Pre-selection
Gas
W-FM internal
9
HoursRun
BurnerID
HoursRun is read only. Reset of the individual counters is

only possible in level Param & Display in menu HoursRun
(see Ch. 9.14).
Here, the burner specific serial number is saved at the

factory. Using the serial number it is possible to replace a
failed unit with one that has the same factory pre-settings.
BurnerID also acts as copy protection; this means burner
specific data in the memory of the ABE cannot be
transferred to another W-FM.
StartCounter
The burner starts are read only. Reset of the individual start
counters is only possible in level Param & Display in menu
StartCounter (see Ch. 9.15).
OptgModeSelect
Here, the operating mode of ABE for serial interface is set.
Fuel meter
see Ch. 9.16 Param & Display - fuel meter
LockoutCounter
Total number of lockouts since commissioning (cannot be
reset).
CombEfficiency
Display of the current efficiency during burner operation
(see Ch. 9.7.1).
InterfacePC
The ABE acts as PC interface. The W-FM is set using a
PC and software.
GatewayBASon
Access by building management (BMS) to the W-FM
using the ABE. The ABE remains functioning.
GatewayBASoff
Operation without building management. Access to the
W-FM only with ABE.
Type of Gateway
Stipulated by the relevant bus protocol (eBus or Modbus).
9.4 Manual operation

Target rating
0-100%
Load started in manual operation (burner On). if not
specified, partial load is started.
S1-S3
Highest stage which can be started in manual operation
(burner On).
Auto / Manual / Off
Burner operation is set using this parameter.
This menu is also accessible from level RatioControl.
Automatic
The burner is regulated by an external or the internal load
controller to set point. Regulation can be two stage, three
stage or modulating.
Manual On
The burner starts and is switched of by the external or
internal temperature guard. Prerequisite is a closed control
circuit or bridge at input X5-03 terminals 1 and 4.
Manual Off
Burner switches off. Even if the switch on hysteresis is not
reached, the burner remains off.
55
9
9.5 Burner control
Depending on the password entry the relevant parameter
for the operator or the engineer is displayed.
9.5.1 Times
Time start up 1
Time general
Fan run up time

Duration of fan start up to start of stepping motors.
Alarm delay time

This time stipulates how soon the combustion manager
signals lockout. The self-test of the system can take up to
35 seconds. If the fault has been rectified during this test
phase, the installation re-starts.
Pre-purge time gas/oil

Duration after reaching the pre-purge positions up to drive
to ignition positions.
Time start up 2
Delay Start Prevention

This stipulates after how many seconds the display
message is shown if start prevention is active during heat
demand.
The interval times act as stabilisation periods following

flame formation. The interval time 2 is only active with pilot
ignition.
Time shutdown
MaxTime_LowFire
If the burner is shut down, or if fuel change over is initiated,
the shutdown program starts at the latest after completion
of this time. If low fire is reached prior to this time elapsing,
the shutdown program starts when low fire is reached.
Post-purge time 3
Duration of post-purge.
9.5.2 Configuration
Configuration general
ConfigFlame Sensor
Alarm start prevention

Stipulates if start preventions are signalled by the alarm
output (terminal X3-01:2)
Flame signal
Display of the current signal at the flame sensor.
ForcedIntermit
With ForcedIntermit active, a controlled shutdown with
immediate restart is carried out after 23 h 50 mins.
9.5.3 Product ID and software version

Product ID
SW version
The ProductID gives information about:

Type description (LMV...)
Production date
Serial number
Parameter set codes
Parameter set version
The SW Version gives information about the software

version of the burner control.
56
9
9.6 Ratio control
The setting parameters in menu RatioControl can only be
accessed with the password for the engineer.
9.6.1 Settings gas/oil

SpecialPositions
The special positions are fuel specific and can be entered
individually for oil and gas.
Home positions
This parameter is used to set the stepping motor positions
or speed control in Standby.
HomePosFC = 0
Frequency converter deactivated
HomePosFC > 0
Start release frequency converter
Fan motor starts with relevant
speed set (in %).
Ignition positions
This parameter is used to set the stepping motor positions
and speed for ignition. Ignition (phase 38) is only carried
out when all motors have reached their ignition positions.
IIgnPosGas
: Ignition must be carried out with excess

air. The gas pressure has to be set to the
instructions given in the installation and
operating instructions of the burner.
Gas butterfly opening during ignition:
with ignition pilot 10 to 20<)
without ignition pilot approx. 10<)
IgnPosOil
: Position of the oil controller. The ignition

position for oil can be found on the burner
test data sheet. The indicator position
given is the same as the data given for the
degree of angle. If an oil controller is not
fitted (multi-stage) the ignition position of
oil has no influence.
IgnPosAir
: When the fuel is ignited a pressure

increase occurs in the combustion
chamber. The burner must create a
resistance against this to avoid a back
flow of flue gases. Therefore ignition with
open air damper and matching of the
mixing pressure by speed only is not
possible. A setting of approx. 30<) for the
air damper is recommended. The actual
air damper opening will be determined
later by the mixing pressure measurement.
IgnPosAux
: The position of the adjustable mixing head

can be found in the installation and
operating instructions of the burner. If an
adjustable mixing head is not fitted, the
fixed sleeve or the adjustable flame head
must be pre-set to the operating points in
the capacity graph.
Reset ignition position

The values of ignition position for oil, air and auxiliary motor
are deleted, existing programming points remain.
The burner without ignition position data can no longer
start.
IgnPosAux2
IgnPosAux3
: Auxiliary motors for special applications.

: For example: Second fuel Kerosene or
Liquid Petroleum Gas, flue gas damper
etc.
(only W-FM 200)
Note: In its delivered condition a provisional ignition

position has been set, for fuel oil also the program
point P1 (these values are needed for burner
testing).
To ensure that the burner does not start at the
installation, a program has been set in phase 36.
IgnPosFC
: The ignition speed depends on the fuel

and should not be below 70% for gas and
80% for oil. If the mixing pressure for
ignition is outside of the limit, correction
must be made using the air damper or
mixing head position (only in connection
with a frequency converter / W-FM 200).
Pre-purge positions
This parameter is used to set the air determining stepping
motor positions or the motor speed for pre-purge.
Pre-purge only starts once all motors have reached their
pre-purge positions.
Post-purge positions
The parameter PostpurgePos allows separate setting of
the individual stepping motors.
Pre-set values have been entered at the factory. Generally,
setting values are required, which ensure sufficient cooling
of the mixing head whilst still maintaining adequate heat in
the heat exchanger.
The speed of the frequency converter must not be set
below 10%.
Program stop
In menu, ProgramStop the start of the burner can be
stopped at 7 defined positions and adjustments to the
burner settings can be made.
24 PrePurgPos
32 PreP FGR
36 IgnitPos
44 Interv 1
52 Interv 2
72 PostPPos
76 PostPFGR
: Nominal load pre-purge position

: Nominal load pre-purge for FGR
: Ignition position without ignition
: End of first safety time
: End of second safety time
: Air damper in post-purge position
(shutdown)
: Air damper in post-purge position
for FGR
57
9
Curve parameters (modulating)
90
100
80
90
Speed %
Starting at the first load point reference lines for the

maximum stepping motor position are created up to full
load (100%), if no other load point is defined.
Manual load increase starting from point P1

Motor positions <)
Increase load manually

Due to burner testing load point 1 (P1) has been factory
pre-programmed for fuel oil. If P1 has been deleted the
W-FM suggests the ignition position as load point 1.
80
70
70
60
60
If the load is now increased in menu curve

parameter/manual, the stepping motors and the frequency
converter are driven by the predetermined reference lines.
50
Set intermediate load points

When nearing the combustion limit, a further load point has
to be set and combustion optimisation has to be carried out.
30
Once the new load point has been saved, a new reference
line is created. The reference lines are drawn between the
previous and the new load point and are further extrapolated. in manual load increase, the stepping motors are
now driven on the basis of the new reference lines.
10
50
40
40
Gas: Due to the control characteristic of the gas butterfly

this should be set to 65 to 70. The gas throughput
has to be determined and adjusted using the setting
screw on the pressure controller.
P2
20
10
P1
0
10
20
30
40
50
60
70
80
90
100
Rating %
Curve lines after saving P2

90
100
80
90
Speed %

The required nominal load in full load has to be set with the
fuel throughput.
20
Motor positions <)
This procedure is repeated until full load has been

reached.
30
80
70
70
60
60
50
50
40
40
Oil: Set required pump pressure in accordance with the

information given in the installation and operating
instructions or the burner test data sheet. Determine
oil throughput and adjust using the setting of the oil
controllers stepping motor.
20
30
20
P2
10
10
P1
0
10
20
30
40
50
60
70
80
90
100
Rating %
90
100
80
90
80
70
70
60
P5
60
Due to the changes made to the mixing pressure and the

speed the fuel quantity throughput should be checked and
adjusted if required.
The pump or gas setting pressure must not be alter once
this process has been completed.
50
50
P4
40
40
30
20
30
P3
20
P2
10
10
P1
0
10
20
30
40
50
60
70
80
90
100
Rating %
58
Speed %
Drive to full load and optimise

Motor positions <)
For the air quantity setting this means, that the speed is set
to a minimum, depending on the load and the emissions,
however not below 40Hz (80%). If at all possible, the
position of the mixing head should be set for maximum
mixing energy and the air damper should be set to the
effective point. With additional O2 control, this will ensure
an effective involvement of the air damper.
Determine combustion limit at full load and set excess air.

Excess air:
without O2 control approx. 15 to 20%
with O2 control approx. 20 to 25%
30
9
100
80
90
80
70
70
60
P4
P5 60
50
50
P3
P4
40
40
30
3
2
20
30
P2
P3
20
P2
10
10
P1
When saving the intermediate load point, an automatic resorting of the load points is carried out according to the
load.
This means: The new point 8 now becomes point 7,
point 7 becomes point 8.
Note: If O2 control is used, point P2 forms the minimum

O2 control load.
For loads below P2, the O2 control is deactivated
and the burner runs on the normal ratio control
curve.
Point P1 is important for the air ratings reduction of
the O2 control. This must have sufficient distance
to P2.
Recommendation: P1 minimum 30% below P2
10
20
30
40
50
Example;
Current throughput at point 7 (70%):
Throughput full load:
250m /h
340 m3/h
80
90
100
90
100
80
90
80
70
70
60
P7
P8 60
50
50
40
40
P8
P7
P6
Load assignment
Once the curve points have been saved, they automatically
sort themselves according to the load assigned to them.
The percentage load assignment depends on the current
and full load fuel throughput.
If the calculated load deviates too much from the load

point, the fuel throughput can be matched by adjusting the
stepping motor position.
70
Enter intermediate load points
30
Current throughput
Load [%] = x 100%
Full load throughput
60
Rating %
Motor positions <)
It is possible to optimise ratio control with up to 15 points.
Speed %
90
Speed %
Insert load points

If a new load point is inserted, its number is always the
number of existing load points plus one. In setting
Manual the load is set with the burner in operation to the
value at which the load point is required (recommendation:
all 10%).
Carry out combustion optimisation and once the fuel
throughput has been determined, carry out load
apportionment. To achieve an even speed curve line, the
speed should not be adjusted during combustion
optimisation.
Delete intermediate load points

Motor positions <)
Deleting points
If a curve point is deleted, the numbering is automatically
changed to the next point. The reference line will then run
linear with the neighbouring points.
30
P5
20
2
1
10
P1
0
10
P4
20
P3
P2
20
10
30
40
50
60
70
80
90
100
Rating %
1
2
3
4
Air damper
Fuel
Mixing head
Speed
manually started load points
Saved load points
Deleted load points
250 m3/h
Load [%] = x 73,5%
340 m3/h
In this case the fuel throughput (P7) can be reduced with
the fuel motor, the combustion optimisation now has to be
repeated.
59
9
Curve parameter (multi-stage)
The operating mode multi-stage is only possible in oil
operation. Depending on burner version two or three stage
operation is available. A three stage burner can also
operate in two stage mode with low impact start.
On and off switch point - 2 stage operation

BS2
Set operating and switch points

The setting of the operating and switch points can be
carried out with or without starting up. By turning the dial
knob the positions of all operating and switch points
entered can be viewed. This does not have any effect on
the system. Even if with start up is selected the stepping
motors do not follow!
AS2
ES2
Without start-up
The stepping motor positions can be set without the
motors following; they remain in the required load set
under manual operation.
BS1
With start-up
By pressing the ENTER button the point called up is
started and the motors follow the current settings made
with the dial knob.
The on and off switch points are also started, however the
valve does not yet switched at the on and off switch point.
This procedure is required to optimise the air quantity to
the fuel quantity.
If the burner is set to Off in manual operation, only the
stepping motors follow, the solenoid valves of the
individual stages, however, are not operated.
Operating points
BS1: Stipulates the air quantity for fuel quantity for
stage 1 (excess air approx. 20 to 25%).
BS2:
Stipulates the air quantity for fuel quantity for

BS3:
Stipulates the air quantity for fuel quantity for

Switch on point
Only once the switch on point has been exceeded will the
solenoid valve for the next stage open. This means the
solenoid valve of the next stage remains closed at the
direct start of the point. This allows the flame stability can
be checked prior to switching to the next stage.
Switch off point
If the burner is reset by one stage, the relevant solenoid
valve will close when the switch off point has been
exceeded (stage 3 or stage 2).
A direct start of the switch off point is not recommended,
as the solenoid valve of the higher stage will remain open,
which leads to soot due to insufficient air.
60
Solenoid valve
stage 2 opens
Solenoid valve
stage 2 closes
9
Load limits
Using the parameter min and max load, the burner can be
limited fuel specific in its load range within the
programmed curve lines.
MinLoad_Gas/Oil
Limits the load range downwards (low fire).
The min load cannot be set below point 1 and if used with
O2 control not below point 2.
MaxLoad_Gas/Oil
Limits the load range upwards (full load).
9.6.2 Times
The duration of the slowest motor across a setting section
of 90 is important for parametering the drive times.
OptgRampMod
DriveRamp
Gives the run time of the motors in modulating operation.
Gives the run time of the motors during the operating

phase without flame.
OptgRampStage
Gives the run time of the motors in multi-stage operation.
9.6.3 Switch off behaviour

Using the parameter Switch off behaviour it is stipulated,
how the ratio control behaves during lockout.
SM stopped
HomePos
The stepping motors remain in the position at the time of

lockout.
At lockout the motors drive to the given home positions.
Post purge
If lockout occurs the combustion manager carries out a
post purge.
9.6.4 Programme stops
In menu programme stop the commissioning of the burner
can be interrupted at 7 pre-defined positions and the
burner setting adjustments can be made.
24 PrePurgP
32 PreP FGR
36 IgnitPos
44 Interv 1
52 Interv 2
72 PostPPos
76 PostPFGR
: Nominal load pre-pre purge position

: Nominal load pre-purge for FGR
: Ignition position without ignition
: End first safety time
: End second safety time
: Air damper in post purge position
(shutdown)
: Air damper in post purge position for
FGR
61
9
9.7 O2 control and guarding
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered (only W-FM 200).
9.7.1 Setting Gas/Oil

The following parameters are fuel specific and can be
entered separately for oil and gas.
Operating mode
auto deact
Is activated automatically, if the O2 control is switched off
in operating mode RegAuto deact.
O2 controller and guard are deactivated and ratio control
drives on the curve lines programmed. At the same time a
warning message appears in the display. Manual activation
of operating mode is not recommended.
man deact
O2 controller and guard are deactivated. The systems
drives on the parametered ration control curve lines. The
burner starts with cold sensor (only for commissioning, not
recommended for normal operation).
O2 guard
Only the O2 guard is active.
If the O2 sensor has not reached operating temperature,
start is prevented.
If the O2 guard reacts, or if a fault occurs in connection
with the O2 measurement, the O2 module or the O2 sensor,
a safety shutdown is initiated. If repetition is not possible
lockout occurs.
O2 control
Using this parameter an O2 set point standardisation has
to be carried out at each point.
The air determining stepping motors are driven down on
the programmed ration control curve lines in line with the
standard values given. The air load this reduced, but the
fuel quantity remains unchanged.
During standardisation of point 2 and the last load point
(full load) the PI control parameters are determined. In
these two points the O2 ratio control value is started after
the standardised value has been saved and the
reactivation time (Tau) is determined. This means the delay
time between changes to the air stepping motor positions
and the actual value at the O2 sensor are determined.
62
O2 controller
The O2 controller and guard are active. The same data
applies as for O2 guard.
conAutodeact
The O2 controller and guard are active. Start-up is carried
out prior to the operating temperature of the O2 sensor
being reached. Activation of the O2 control in operation is
only carried out once the operating temperature has been
reached and the sensor test has been successful.
If the O2 guard reacts, or if a fault occurs in connection
with the O2 measurement, the O2 module, the O2 sensor
or the sensor test, the O2 controller and O2 guard are
deactivated automatically.
The system drives to the O2 ratio control setting. The
operating mode is set to auto deact. The ABE displays
the note about the automatic deactivation. The fault code
remains until the operating mode is changed.
9
O2 Guard
The O2 min limit can be entered directly if the combustion

limit has already be determined, or it can be determined by
reducing the air load.
Direct input:
If the O2 values on the combustion limit are already known
these can be assigned as O2 min value for the Guard
function.
O2 min limit
3,0
2,5
O2 content [%]
Using this parameter, an O2 limit value has to be set for

each point (CO/soot).
If during operation, the O2 min limit is not reached for
3 secs. this leads to either a safety shutdown or an
automatic deactivation of the O2 control / guarding
function, depending on the operating mode selected.
2,0
1,5
1,0
0,5
0
Determination:
Using P-Air manual reduce air load until the combustion
limit (CO/soot) has been reached and save the O2 actual
value displayed as limit value.
10
20
30
40 50 60
Burner rating [%]
70
80
90
100
O2 min limit for guard function

Increased O2 min value with steep CO increase at the
combustion limit (+0.2 to 0.3 % points)
Note If the CO increases sharply at the combustion limit,

the O2 min value for the guard function can be
selected 0.2 to 0.3% points higher.
Control parameter
O2 control behaviour
Pre-control becomes active at entry into the load control

after 10 x Tau low fire. If during the delay time full load no
load changes occur, the O2 control becomes active.
Using the control parameter the behaviour of the O2

control can be influenced.
4
1
Load [%]
At each load change the actual load is calculated. If the

difference of the reference line exceeds the LoadContLock
value the O2 control is stopped.
If the load signal remains constant and the difference is not
exceeded, the O2 control becomes active again once the
delay time full load has elapsed.
O2 Currual value
O2 set point
O2 content [%]
The O2 control is supported by the pre-control function.

If equal ambient conditions are present, the pre-control
calculates the air load reduction for the total load range. If
the load signal changes, a setting size alteration (air) of the
ratio control is carried out by the pre-control. This means,
the O2 control only has to adjust deviations in ambient
conditions (temperature, air pressure, ...).
1
2
1
2
3
4
5
parameter LoadContLock
locked range
Delay time full load ( 2 x Tau full load)
Burner load
Following actual load
P Low/high fire
Proportional part of O2 control.
Tau high fire

Reaction time at 100% determined during standardisation.
I Low/high fire
Integral part of O2 control.
LoadContLock
Limit value of the load difference from which the O2 control
is locked.
Tau low fire

Reaction time in point 2 determined during
standardisation.
FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.
O2 Offset Gas/Oil
Increase of O2 content before a load increase is carried
out.
63
9
O2 control limit
For burner ratings below the set value, the O2 control is
deactivated and the system drives on the programmed
curve lines of the ratio control. If the burner rating
increases to 5% points above the control limit, the O2
control is reactivated.
Type of Fuel
To calculate the combustion efficiency the fuel currently
used must be set.
If the fuel is not available, its fuel values can be entered
under FuelUseDef.
In parameter FuelUseDef the calculation values for the
combustion efficiency will be displayed.
The values
V_Lnmin = Air volume under normal conditions at 1
V_afNmin = Flue gas volume wet under normal cond. 1
V_atrNmin = Flue gas volume dry under normal cond. 1
are required for converting O2 wet to O2 dry
A2
= Adjustable constancies for F
B/1000
= Adjustable constancies for F
are constancies depending on the fuel.
Type air change

Influences the calculation procedure for pre-control.
As P Air:
A change in air density (temperature pressure) will affect
the fuel throughput.
Recommended setting for fuel Gas.
LoadContLock
Limit value of the load difference from which the O2 control
is locked.
FilterTimeLoad
Lock time after which a load change in the size of the
LoadContLock can be made.
O2 Offset gas/Oil
Increase of O2 content before a load increase is carried
out.
9.7.2 Process data
The menu process data is read only:
about the current combustion efficiency
about the setting size of the O2 controller
release of O2 controller (activated/deactivated)
current load of the air determining motors
diagnostic codes if the controller is locked
64
In theory:
A change in air density (temperature pressure) will not
affect the fuel throughput.
Recommended setting for fuel Oil.
9
9.8 LoadController
Here, the relevant parameters for the operator or the
engineer are displayed depending on the password
entered.
On W-FM 100 the load controller is optional.
Note: To set the internal load controller this must be
activated in SystemConfig (Ch. 9.13).
9.8.1 ControlParam Select

ReglerParam Wahl
Under (StandardParam) 5 standard parameter sets and
the adaption PID values can be accessed. Each one of
these parameter sets can be copied direct into the PID
memory, the existing values will be overwritten.
StandardParam
very slow
slow
normal
fast
very fast
Adaption
P (Xp)
I (Tn)
D (Tv)
30 %
400 s
10 s
15 %
320 s
40 s
7%
90 s
50 s
4%
35 s
17 s
40 %
55 s
15 s
values determined during adaption
Adapt control parameters

Xp too small
Xp too large
Tn, Tv too small
Tn, Tv too large
The control parameters can also be entered manually:

P-Part (Xp):
I-Part (Tn):
D-Part (Xv):
Proportional band
Integral action
Derivative action
MinActuatorStep
The smallest possible correcting element step is used for
setting value damping.
If the difference between the new calculated setting size
and the current setting size is smaller than
MinActuatorStep, the current setting size is maintained.
SW FilterTmeCon
Using the filter time actual value fault signals, which
predominantly affect the D content, can be weakened.
However, if the filter time is too long this influences the
actual value determination and has a negative effect on the
control accuracy.
A filter time of 2 to 4 seconds should be set for automatic
adaption. If the time selected is too long this can lead to
automatic adaption being stopped.
Set points W1/W2
Switchover from set point W1 to W2 is by potential free

contact at input X62:1/2
Set point switchover W1/W2
X62
Two set points (W1/W2) can be set for the internal load
controller. The set points can not be set above the current
limit temperature.
Activation
2. set point
2
1
W2
65
9
SD_M
ModOn/Off
Switch difference in percent for modulating operation.
With positive SD_ ModOn the switch difference is above
the set point, with negative below.
SD_S
Stage On/Off
Switch difference in percent for modulating operation.
With positive SD_Stage1On the switch difference is
above the set point, with negative below.
ThresholdStage... On
If control deviations occur an integral is created over the
time.
If the integral drops below the ThresholdStage...On the
next stage is switched. This can influence the switching
frequency of the individual stages.
Switch ThresholdStage... On
Actual
value
Set point
SD_Stage
1 On
Stage 2
Stage 3
Q2
Q2
Q3
O2 = switch threshold stage 2 (ThresholdStage2On)

O2 = switch threshold stage 3 (ThresholdStage3On)
9.8.2 Temperature switch

The temperature switch is only active in connection with
the relevant sensors (see Ch. 9.8.4).
The TL_ThresholdOff stipulates the temperature at which
the installation is switched off. Once the switch on
hysteresis TL_SD_On is reached, the installation is
released again.
66
9
9.8.3 Cold start
ColdStartOn
Activates/deactivates the cold start function. The cold start
function ensures that the boiler is not operated at its
maximum loading if the preset minimum boiler temperature
has not been reached.
This operating mode protects the material of the boiler.
Threshold On
Switch on threshold in percent relating to the set point
(W1/W2) or Setpoint AddSens.
The cold start function is started if the boiler temperature is
below this switch on threshold at heat demand.
Cold start function
Set point
Threshold
Off
StepSetpoint
Threshold
On
Actual
value
appliance
Step Load (modulating)
Cold start load modulating
The cold start load increases by this value, when the boiler
temperature has reached the next set point step. If the set
point step is not reached, the cold start load is increased
after completion of the parametered MaxTmeMod.
Step load
Step Setpoint m/s

Stipulates the cold start set point increase.
If the boiler temperature reaches the current cold start set
point, this is increased by the given value.
Low fire
MaxTmeMod
Cold start load multistage
MaxTime
MaxTimeMod:
Time after which a load increase is carried out (modulating
operation).
MaxTimeStage:
Time after which the next stage is released. Pre-requisite is
that Release Stages is activated.
ThresholdOff
Switch off threshold in percent relating to the set point
(W1/W2) or Setpoint AddSens. Once the switch off
threshold has been reached the installation switches to
control operation.
Stage 3
Stage 2
Stage 1
MaxTmeStage
Release Stages
Additional sensor
Not released:
Cold start only in the first burner stage. Stage 2 and stage
3 are locked during the cold start.
Activates the temperature sensor on terminal X60.

The additional sensor is required if a pressure sensor has
been fitted to terminal X61 and if start-up is to be carried
out with media temperatures below 100 C.
Released:
Cold start is carried out in the first burner stage. Once the
boiler temperature reaches the current cold start set point,
the next stage is released.
Setpoint AddSens
If the additional sensor has been activated this set point is
the reference size for the on and off switch threshold of the
cold function.
67
9
9.8.4 Configuration load controller
LC operating mode
The load controller setting (internal/external) in
SystemConfig has priority. This means that if an external
load controller has been activated in SystemConfig,
operating mode selection is not possible.
int LC Bus
The building management system stipulates the set point
for the internal load controller. Signal switchover is carried
out by the ABE and an additional eBus interface. For this
the gateway has to be activated in menu Operation,
parameter Select operating mode (Ch. 9.3) and the Bus
protocol (Gateway type) has to be entered. If the Gateway
type ModBus has been selected, the ModBus must be set
to local in menu AZL(ABE) (Ch. 9.9.6).
X5-03
int LC
Activates the internal load controller. Set point (W1/W2)
are set using the ABE.
If a different operating mode is selected, the int LC
operating mode can be activated using one of the switch
contacts on terminal X62:1/2. In this case, control is to set
point W1.
The internal load controller must be configured and
optimised to carry out this function.
External LC on input X5-03
Stage 1
Stage 3
Closed
Stage 2
Open
On
C
4
3
2
BMS
420 mA
010 V
ext. switch contact
Int LC
External set point / load input via Bus
BMS
int LC X62
The building management system stipulates an analogue
signal as set point for the internal load controller. The
setting range automatically matches itself to the
parametered measuring range of the sensor
(MeasureRange PtNI). Additionally, it is possible to limit
the set point range both up and down (Ext SetPoint ...).
ext LC X62
The building management system stipulates an analogue
load signal (tab. External load input). The W-FM converts
the signal and starts the relevant motors or the frequency
converter.
LC
Ext. analogue signals and switchover to int. LC
X62
extLC X5-3
Load control is via three-point step signal of an external
controller at input X5-03. The input must not be switched
with radio interference suppressors.
eBus
Interface
W-FM 200
Load signal output - only with internal load controller -
Modulating
Multistage
Analogue
signal
Low fire High fire Stage 1 Stage 2 Stage 3
X63
External load input
2
1
I (mA)
20
10
15
U (V)
10
2,5
7,5
Ext LC Bus
Load control is carried out by the building management
system. Start-up is carried out by the ABE and an
additional eBus interface. For this the gateway has to be
activated in menu Operation, parameter Select operating
mode (Ch. 9.3) and the Bus protocol (Gateway type) has
to be entered. If the Gateway type ModBus has been
selected, ModBus must be set to remote in menu AZL
(ABE) (Ch. 9.9.6).
68
0
420 mA
For the operating modes with internal load controller a load

signal of 4 to 20 mA is given to output X63:1/2.
4 mA 0% load
20 mA 100% load
9
Senor selection
PT100
PT 100 sensor on terminal X60:1/2/4 (three core switching)
temperature limiting function is active.
Sensor connection
PT1000
PT 1000 sensor on terminal X60:3/4
temperature limiting function is active.
X60
Pt 100
Pt/Ni 1000
4
3
2
1
Ni 1000
Ni 1000 sensor on terminal X60:3/4
temperature switch function is active.
PT100 PT1000
for temperature switch function.
PT1000 sensor on terminal X60:3/4 for temperature
limitng function.
PT100 Ni 1000
for temperature switch function.
Ni 1000 sensor on terminal X60:3/4 for temperature
limiting function.
PressSens
Pressure sensor at input X61
no limiting function.
Sensor connection
P/
X61
TempSensor
temperature sensor at input X61
no temperature limiting function.
420 mA
2
1
010 V
20V DC
none
No sensor connected to W-FM (i.e. external ratings input
without temperature guarding function).
Measuring range PtNi
The start of the measuring range is fixed at 0 C or 32 F
and cannot be altered.
The end of the measuring range can be configured.
Two possibilities are available:
150 C/302 F or 400 C/752 F
Valid for Pt100:
Load balancing of the three core switching is not required,
if the resistance of the connecting lines are equa
Ext Input X61 U/I
Input X61 has to be configured depending on the sensor
used.
4...20 mA : Current signal to terminal X61:3
with line guarding
2...10 V : Voltage signal to terminal X61:2
with line guarding
0...10 V : Voltage signal to terminal X61:2
without line guarding
The supply voltage (20V DC) on terminal X61:1 cannot be
altered.
69
9
MeasureRange TempSens / PressSens
The measuring range of the temperature or pressure sensor
can be parametered freely within the preset limits.
MeasureRange TempSens: 0 to 2000 C or 32 to 3632 F
MeasureRange PressSens: 0 to 99.9 bar or 0 to 1450 psi
Values 105 outside of the measuring range are interpreted as
sensor short circuit or as line break.
Ext Input X62 U/I
If an external load or set point signal is switched at terminal
X62, the analogue signal has to be defined.
4...20 mA : Current signal on X62-/4
Load or set point signal with line monitoring
2...10 V : Voltage signal on X62:2/4
Load input with line monitoring
0...10 V : Voltage signal on X62:2/4
Set point input without line monitoring
Ext Setpoint min/max

The external analogue set point signal is applied as a
percentage in the internal load controller to the
temperature range set under MeasureRange PtNi.
Temperature inputs outside of this limit will not be included
into the control by the load controller, even if the external
input does not reach or exceeds these values.
Set point input
Measure Range
PtNi
Current signal
Voltage signal
4 mA
20 mA
0V
10 V
0150C
0C
150C
0C
150C
0400C
0C
400C
0C
400C
Example 1 (set point signal in mA):
Example 2 (set point signal in Volt):
Upper set point limit required = 80 C
Lower set point limit required = 50 C
MeasureRange PtNi
150 C
MeasureRange PtNi
400 C
ExtInput X62 U/I

40 to 20 mA; corresponds to analogue range of 16 mA
ExtInput X62 U/I

0 to 10 V; corresponds to analogue range of 10 volt
Calculation
Calculation:
80C
150C
50C
100 53,3%
400C
Corresponds to a set point signal of

16 mA
150C
70
80C
+ 4mAOffset
100 = 12,5%
Corresponds to a set point signal of

12,53 mA
10 V
400C
50C
1,25 V
9
9.8.5 Adaption
Start adaption
The adaption allows the load controller to automatically
identify the control section and to create the PID
parameter from the data determined. Adaption is available
for both temperature and pressure control. The adaption
can be started in manual or automatic operation; the
installation can be in operation or standby.
Adaption is not possible in multi-stage operation.
Adaption Load
With this parameter, the adaption load can be reduced by
up to 40%. This could be necessary, if the heat demand
during adaption for full load (100%) is insufficient and the
installation switches off during the adaption process.
If the adaption load is selected so low that the set
temperature is not reached this leads to interruption of the
adaption.
9.8.6 SW version
The SW Version supplies details about the software
version of the load controller.
71
9
9.9 ABE
9.9.1 Times
Sum/Winter time
Time EU/US
Manual or automatic changeover from Summer to Winter

time can be selected.
European or American Summer / Winter times can be

selected.
9.9.2 Language
Six languages are available for selection.
If the required language is not available the language
group can be overwritten with PC software. A total of 4
language groups, each with 6 languages, are available in
the software.
9.9.3 Date format

Available for selection are the European format: DD, MM,
YY or the international format: MM, DD, YY.
9.9.4 Physical units

Temperature can be selected as degrees Celsius or
degrees Fahrenheit, pressure in bar or psi.
9.9.5 eBus
Adress
Send Cycle
Here the eBus address of the W-FM is set, which the

building management uses to communicate with the
combustion manager.
Here the cycle time for sending operating data of the

combustion manager to the BMS is set.
72
9
9.9.6 Modbus
Adress
Local / Remote
Here the Modbus address of the W-FM is set, which the

building management uses to communicate with the
combustion manager.
In Local setting the internal load controller of the

combustion manager becomes active.
In remote setting, the building management system is
active.
Baudrate
Remote Modus
The baudrate stipulates the transfer speed.

The baudrate of the combustion manager and the BMS
must be identical.
The parameter is read only, input is by BMS.
Parity
Parity is a safety feature for data words during transfer.
The parity of the combustion manager and the BMS must
be identical.
Remote Auto : Set point input W3 by BMS

Remote on
: Set degree input by BSM
Remote off
: The internal load controller is active
W3
Set point input press or temperature by BMS.
Timeout
This time stipulates, after what time the ABE automatically
switches from remote to local if Modbus communication
fails.
This means the building management system is
deactivated and the internal load controller of the W-FM
takes over control.
9.9.7 Display contact

With this selection the dial knob is active and the required
contrast can be set and saved.
The display contrast can also be altered without saving it.
To do this turn the dial knob left or right whilst holding
down the ENTER button (only possible in the operating
display normal operation).
9.9.8 Product ID and SW Version

Product ID
SW Version
The Product ID gives information about:

Type description (ABE)
Production date
Serial number
Parameter set code
parameter set version

version of the display and operating unit (ABE).
73
9
9.10 Stepping motors (Actuators)
9.10.1 Addressing
If only one stepping motor is changed the addressing and
the rotational direction will remain the same. If more than
one stepping motor is changed, a new address has to be
entered for each new motor.
Addressing stepping motor
Bus connection
If the stepping motor is the last unit in the bus line,
a bus connection has to be made using a jumper. The bus
connection on all other units must be deactivated (the ABE
has a fixed bus connection).
Addressing stepping motors
Select relevant motor in the menu and confirm with Enter.
Then start the address assignment by pressing Enter and
press the address button on the stepping motor to be
addressed.
Following addressing the LED shows the flashing code
and the display shows a confirmation message.
Address button
LED
Jumper
Delete address
If a wrong address has been entered, this can be deleted
by pressing the push button on the stepping motor for 10
seconds, if necessary disconnect the mains voltage whilst
holding down the button. The LED will return to continuous
illumination.
Flashing codes
Air stepping motor
Gas stepping motor (Oil)
Oil stepping motor
Auxiliary motor
Auxiliary motor 2
Auxiliary motor 3
1 impulse
2 impulses
3 impulses
4 impulses
5 impulses
6 impulses
without bus
connection
with bus
connection
LED continuous illumination = no address

LED continuous flashing = addressing in progress
LED flashing codes = addressed
9.10.2 Rotation direction

DeleteCurves
Deletes curve lines of all stepping motors, only required to
change the rotation direction in menu level OEM.

Product ID
SW Version

Type description (stepping motor)
Production date
Serial number
Parameter set code

version of the stepping motor.
74
9
9.11 FC-Modul
Depending on the password entered this displays the
parameters for the operator or the engineer (only WFM200).
Speed
Standardisation
During standardisation a set point signal of 95% is given
at open air or auxiliary stepping motor. This means that
there is a shortfall of 5% of the max. frequency set at the
transformer (52.5 Hz x 0.95 = 50 Hz). The speed reached
at the standardised 50 Hz is saved in parameter
Standardised Speed as 100% value for the speed control.
If more than 50 Hz is shown during standardisation, the
motor slip adjustment (=0) on the frequency converter has
to be checked.
If the standardised speed is not reached during operation
at 100%, a reserve of 5% is available to the system.
Note Following speed standardisation or changes to the
speed saved, the combustion values should be
checked.
Set point output

The output signal (0/4 to 20 mA) at terminal X73 of the
W-FM and the input signal of the frequency converter must
have been matched to one another.
To guard the signal line, the setting 4 to 20 mA should be
selected on the W-FM and frequency converter.
Speed determination
180
10 V DC
Pulse
GND
Reserve
Screen
1
X70
Number of impulses per rotation

Speed determination is carried out with an asymmetrical
transmitter (3 impulses per rotation) at input X70. The
asymmetrical transmitter construction (60, 120, 180) is
used for recognising the rotation direction, motor start with
the wrong direction is therefore not possible.
2
3
4
5
60
2 core
3 core PNP
120
Pulse sequence: 60, 120, 180
Connection Frequency converter
X73
Standardised speed
The speed determined during standardisation is saved in
this parameter and can be altered if necessary (not
recommended).
FC
24 V
Start FC
1224 V DC in (Alarm)
0/420 mA out (Setpoint)
GND
Screen
1
3
4
5
6
Fuel meter
Fuel meters with Namur or Reed output and Open
Collector (pnp) can be used.
The system continually calculates the current fuel
throughput for the fuel selected. Calculation time
is dynamic and is between 1 and 10 seconds.
If the meter does not supply an impulse for 10 seconds,
throughput Zero is displayed. This means that the
transmitter should have a minimum impulse frequency of
0.1 Hz at minimum throughput.
At maximum throughput the maximum frequency is 300 Hz.
Impulse value Gas

Depending on the type of gas meter, m3 or ft3 can be
selected.
Impulse value Oil
Depending on the type of oil meter, l or gal can be
selected.
Fuel meters
Gas
1
X71
Example:
Data on gas meter: 250 impulses per m3
Throughput full load:
20 m3/h ^
= 5000 Imp./h ^
= 1,388Hz
Throughput partial load: 4 m3/h ^
= 1000 Imp./h ^
= 0,277Hz
2
3
4
Oil
X72
1
2
3
4
10 V DC
Pulse
GND
Screen
10 V DC
Pulse
GND
Screen
2 core
3 core PNP
2 core
3 core PNP
Fuel meter
Oil
Fuel meter
Oil
75
9
9.11.2 Process data
The process data is located in the volatile memory and is
reset automatically following lockout.
Max Stat Dev
Num Dev>...
The maximum static deviation shows the largest speed

deviation at the end of value input alteration.
Shows the frequency of static deviations at the end of a

value input alteration, which were > 0.3% or > 0.5%.
Max Dyn Dev
Absolute Speed
The maximum dynamic deviation shows the largest

speed deviation between actual speed and set speed in
multistage operation.
Shows the actual speed.

Product ID
SW Version

Type description (FC module)
Production data
Serial number
Parameter set code

version of the FC module.
76
9
9.12 O2-Module
Depending on the password entered this displays
the parameters for the operator or the engineer (only
W-FM200).
O2 sensor
MaxTempFlueGas ...
To determine O2 the O2 sensor QGO20 has to be

activated.
If the flue gas temperature set is exceeded a warning

message is given. The set limit can be set individual for oil
and gas and indicates increased appliance losses. The set
value should be approx. 20% above the nominal flue gas
temperature of the appliance manufacturer.
Supply air sensor / flue gas sensor

To be able to determine the combustion efficiency the
supply air sensor and the flue gas sensor must be
connected and configured.
9.12.2 Display values

Current O2 value
QGO Heating Load
Current O2 value measured by the sensor QGO20.
Display of the actual heat rating in %.

The heat rating is in the range of 0 to 60%. The percentage
displayed corresponds to an impulse/pause ratio relating
to 2 seconds and 230 V.
60% heat rating corresponds to 1.2 seconds impulse and
0.8 seconds pause.
After approx. 15 minutes the sensor has reached the set
point of 700 C (pre-requisite for release of the O2 control).
Supply air temperature

Air intake temperature measured by the Pt/Ni sensor.
Used to determine combustion efficiency.
Flue gas temperature

Flue gas temperature measured by the Pt/Ni sensor. Used
to determine combustion efficiency.
Heating Load:
Start heat load up to 100 C ______________approx. 13%
Heat up process
approx. 60%
Operating temperature ______________approx. 15 to 25%
QGO Resistance
QGO SensorTemp
Current operating temperature of the O2 sensor.
The internal resistance is a measure for the function ability

of the sensor. It changes during the operating time.
If the internal resistance is < 5 or > 150 the sensor is
ageing.
9.12.3 Product ID and SW version

Product ID
SW Version

Type description (O2 module)
production date
Serial number
Parameter set code
The SW Version gives details about the software version

of the O2 module.
77
9
9.13 SystemConfig
LC operating mode
TempLimit
The configuration of the load controller operating mode is

identical to that in menu LoadController (Ch. 9.8.4).
However, the setting in SystemConfig has priority.
This means that if an external load controller is selected in
menu SystemConfig you cannot change over to internal
operating mode in menu LoadController.
The configuration of the TL_ThresholdOff and TL_SD_Off

is identical to that in menu LoadController (Ch. 9.8.2).
The configuration for SensSelect and for MeasureRange
is identical to that in menu LoadController (Ch. 9.8.4).
Ext Input X62 U / I

The configuration of the external input X62 is identical to
that in menu LoadController (Ch. 9.8.4).
O2Ctrl/Guard.....
The configuration is identical with that in menu
O2Ctrl/Guard (Ch. 9.7.1).
9.14 Operating hours

Gas operation
TotalOperHoursR
Operating hours for fuel Gas since last reset.
Total operating hours oil and gas since last reset.
Stage 1 / Mod
TotalOperHours
Operating hours of stage 1 or modulating (oil) since last

reset.
Total operating hours oil and gas.

This value cannot be reset.
Stage 2
Unit under voltage
Operating hours of stage 2 (oil) since last reset.
Total hours the W-FM has been connected to mains

voltage.
Stage 3
Reset
Operating hours of stage 3 (oil) since last reset.
Here all parameters, which can be reset, can be set to

Zero.
78
9
9.15 Start counter
Start counter Gas
TotalStartCounterR
Burner starts with fuel gas since last reset.
Total burner starts with fuel oil and gas since last reset.
Start counter Oil
TotalStartCounter
Burner starts with fuel oil since last reset.
Total burner starts with fuel oil and gas.

Reset
Here all parameters, which can be reset, can be set to
Zero.
9.16 Fuel meters

If an oil or gas meter is installed and configured (Ch.
9.11.10), the fuel quantities determined can be called up
and reset here.
Current throughput
Volume Gas R
Displays the current throughput for gas in m3/h or oil in l/h.
Fuel throughput for gas in m3 since last reset. Reset by

pressing the ENTER button.
Volume Gas
Reset date gas
Total gas throughput in m3.

Date of last reset for fuel gas.
Volume Oil
Reset date oil
Total oil throughput in litres.

Date of last reset for fuel oil.
Volume Gas R
Fuel throughput for oil in litres since last reset. Reset by
pressing ENTER button.
79
9
9.17 Updating
9.17.1 Parameter backup
Backup-Info
ABE -> LMV5...
Displays information about the date and time of the last

parameter backup as well as their system components.
Loads the data from the display and operating unit (ABE)
to the base unit (W-FM). Pre-requisite is that the burner
identification of the ABE and the W-FM are identical or
that burner identification of the W-FM is still in its delivery
condition.
The data in the W-FM are overwritten and can no longer
be reproduced.
LMV5... -> ABE

Loads the data from the base unit (W-FM) to the display
and operating unit (ABE).
Any data in the ABE is overwritten and can no longer be
reproduced.
9.17.2 Load SW from PC

Updates the software of the display and operating unit
(ABE) with PC-Tool using a serial interface.
9.18 Password
PW login
Deactivate PW (PW Logout)
After entering the engineers password additional access

to the engineers level is available. The password is
deactivated 120 minutes after the last input.
Using this parameter the password protected level can be

protected at an earlier stage.
9.19 TV test
LossFlameTest
SLT Test
The flame failure test interrupts the flame sensor signal and
it can be checked if the W-FM will go to lockout.
During the SLT Test the control circuit as well as the

temperature guard are bridged and the burner is operated
at maximum load, allowing the response of the safety
temperature limiters to be checked.
80
Gas + Oil
Times
Inputs
Gas
Gas + Oil
Output
Gas
X10-02: 6 q
X3-02: 1 1
X4-01: 3
X4-01: 3
X9-03: 2
X9-03: 4 3t
X7-03: 1 3w
X9-03: 3 3
Gas pressure switch GPSVP X9-03: 2
Burner motor / Fan
X3-01: 1
9/0
Ignition
X4-02
u
3-way solenoid
X4-03
Alarm
X3-01: 2 i N
Safety relay internal
X3-04: 1/2
Safety relay Gas
X9-01: 1
Valve pilot ignition Gas
X9-01: 2
Fuel valve 1 Gas
X9-01: 4
Fuel valve 2 Gas
X9-01: 3
90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Home run
N
N
N
N
49 4
N
N
A
B
B
C
C
C
A
B
B
c
A
G
G
N
N
B
B
B
B
i
A
A
A
A
B
B
N
N
tmx1
B
B
B
B
i
A
A
A
A
B
B
N
N
B
B
B
B
i
A
A
A
A
B
B
N
N
tmx1
B
B
B
B
i
A
A
A
A
B
B
N
N
N
N
4
A
A
A
A
B
B
B
B
B
B
N
N
N
N
N
N
4
D
D
A
A
A
A
D
F
Ignition position
Flame signal ON
N
N
N
N
D
D
A
A
A
A
D
F
N
N
N
N
D
D
A
F
D
F
F
L
A
A
A
t42 t44
44
N
N
N
N
D
D
A
F
D
F
F
L
A
A
A
50
Flame stabilisation
TSA
Ignition OFF
42
N
N
N
N
F
D
F
F
L
A
A
A
a
D
D
A
t52
52
Interval time 2
t38
Fuel valve
ON
40
N
N
N
N
tmx1
F
D
F
F
L
A
A
A
a
D
D
A
54
Low fire position
tmx1
B
B
B
B
Pre-ignition
38
N
N
N
N
D
D
A
G
D
F
G
L
A
A
A
60
Operating phase 1
B
B
B
B
Stepping motor in
ignition position
36
N
N
N
N
D
D
A
L
A
A
A
D
F
A
A
k
A
A
tmx1 tmx1 tmx1
62 70 72
or and
t62 t70
Operating phase 2
t34
34
After burner time
tmx2
B
B
B
B
Pre-purge
32
Air stepping motor in

post purge position
t30
tv
30
k
A
A
t74
74
tn1
t01 tmx1 tmx1

C
B
C
B
C
B
C
B
c
k
A/c A/c
e A/c A/c 9
A/c A/c
C
A

pre-purge position
24
k
A
A
A
A
tmx1
76
Post purge
Fan = ON
21 22
und
t21 t22
Safety fuel
valve = ON
Safety
relay = ON
20
E
E
m
k
A
A
A
A
t78
78
tn3 5
90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Standby
10 12
und
t10
N
N
c
A
H
H
k
c
w
w
tmx2
B
B w
B
79
t0
Safety phase
01
TSA2
Shutdown
Direct start
X4-01: 1
X3-04: 1
Lockout phase
00
TSA1
Operation
Valve proving
81
82
83
N
N
N
N
N
N
A
N
N
i
A
A
A
D
D
7
i
A
A
A
D
D
D
D
i
A
A
A
N
N
a
N
D
D
i
A
A
A
t80 t81 t82 t83
80
Press test
V1 = Closed, V2 = Closed
Fill valve train
V1 = Open, V2 = Closed
Test no press
Empty valve train
V1 = Closed, V2 = Open
Operating phase
Timer-Event- Link
Timer 1
Timer 2
Timer 3 = Phase max. time
Fuel switch GAS
Safety circuit
Temperature guard internal
Controller ON
Flame signal
Air press. switch APS
BrnFan motor aux-contact
or FGR- Fan-PS
CPI or VP-PS
Low gas press.sw. LGPS
Release Gas
Lockout HGPS.
Gas direct ignition
tv
Start up
9.20 Sequence of operation diagrams
Sequence diagram gas with direct ignition
Fuel
Air
Actuators
81
82
Times
Gas + Oil
Inputs
Gas
Gas + Oil
Output
Gas
90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Home run
X10-02: 6 q
X3-02: 1 1
X4-01: 3
X4-01: 3
X9-03: 2
X9-03: 4 3t
X7-03: 1 3w
X9-03: 3 3
X9-03: 2
X3-01: 1
9/0
X4-02
u
X4-03
X3-01: 2 i N
X3-04: 1/2
X9-01: 1
X9-01: 2
X9-01: 4
X9-01: 3
9
8
N
N
N
N
49 4
N
N
A
B
B
C
C
C
A
B
B
c
A
H
H
Air stepping motors in

pre-purge position
tmx1
B
B
B
B
N
N
B
B
B
B
i
A
A
A
A
B
B
N
N
tmx1
B
B
B
B
i
A
A
A
A
B
B
N
N
B
B
B
B
i
A
A
A
A
B
B
N
N
tmx1
B
B
B
B
i
A
A
A
A
B
B
N
N
N
N
4
A
A
A
A
B
B
B
B
B
B
N
N
N
N
N
N
4
D
D
A
A
A
A
D
F
Ignition position
Flame signal ON
N
N
N
N
D
D
A
A
A
A
D
F
N
N
N
N
D
D
A
F
D
F
F
L
A
A
A
t42 t44
44
N
N
N
N
N
D
D
A
F
D
F
F
L
A
A
A
50
Flame stabilisation
TSA
Ignition OFF
42
N
N
N
N
F
D
F
F
L
A
A
A
a
D
D
A
t52
52
Pilot ignition valve OFF
t38
Fuel valve
ON
40
N
N
N
N
tmx1
F
D
F
F
L
A
A
A
a
D
D
A
54
Low fire position
B
B
B
B
Pre-ignition
38
N
N
N
N
D
D
A
G
D
F
G
L
A
A
A
60
Operating phase 1
tmx2
B
B
B
B
Stepping motors in
ignition position
36
N
N
N
N
D
D
A
L
A
A
A
D
F
A
A
k
A
A
tmx1 tmx1 tmx1
62 70 72
or and
t62 t70
Operating phase 2
t34
34
After burner time
t01 tmx1 tmx1

C
B
C
B
C
B
C
B
c
k
A/c A/c
e A/c A/c 9
A/c A/c
C
A
Pre-purge
32

post purge position
t30
tv
30
k
A
A
t74
74
tn1
24
k
A
A
A
A
tmx1
76
Post purge
Fan = ON
21 22
und
t21 t22
Safety fuel
valve = ON
Safety
relay = ON
20
E
E
m
k
A
A
A
A
t78
78
tn3 5
90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Standby
10 12
und
t10
N
N
c
A
H
H
k
c
w
w
tmx2
B
B w
B
79
t0
Safety phase
01
TSA2
Shutdown
Direct start
X4-01: 1
X3-04: 1
Lockout phase
00
TSA1
Operation
Valve proving
81
82
83
N
N
N
N
N
N
A
N
N
i
A
A
A
D
D
7
i
A
A
A
D
D
D
D
i
A
A
A
N
N
a
N
D
D
i
A
A
A
t80 t81 t82 t83
80
Press test
Fill valve train
V1 = Open, V2 = Closed
Test no press
Empty valve train
V1 = Closed, V2 = Open
Operating phase
Timer-Event- Link
Timer 1
Timer 2
Timer 3 = Phase max. time
Fuel switch GAS
Safety circuit
Temperature limit internal
Controller ON
Flame signal
Or FGR-Fan-PS
CPI or VP-PS
Low gas press. sw. LGPS
Release Gas
Lockout HGPS.
Gas press. switch GPSVP
Burner fan motor
Ignition
3-way solenoid valve
Alarm
Safety relay Gas
Valve pilot ignition Gas
Fuel valve 1 Gas
Fuel valve 2 Gas
Gas pilot ignition
tv
Start up
Sequence diagram gas with pilot ignition
Fuel
Actuators
Air
Times
Gas + Oil
Inputs
Oil
Gas + Oil
Output
90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Oil
90 (Full load)
Pre-purge position
Post-purge position
Partial load
Ignition position
Standby position
Home run
8
N
Stepping motors in
ignition position
u
i
Pre-ignition
N
N
N
N
N
N
N
N
N
N
N
N
2
N
N
N
N
N
N
N
N
N
N
A
A
A
A
A
A
D
N
D
D
N
N
N
D
D
D
D
L
A
A
A
A
A
A
D
N
t42 t44
Flame stabilisation
N
N
N
N
D
D
D
D
L
A
A
A
A
A
A
D
N
50
N
N
N
D
D
D
D
L
A
A
A
A
A
A
D
N
t52
52
Interval time 2
Ignition position
Flame signal ON
44
N
N
N
tmx1
D
D
D
D
L
A
A
A
A
A
A
D
N
54
Low fire position
Ignition OFF
42
N
N
N
G
D
D
G
L
A
A
A
A
A
A
D
N
60
Operating phase 1
34
N
N
N
N
N
N
L
A
A
A
A
A
A
D
N
D
D
N
N
A
A
k
A
A
tmx1 tmx1 tmx1
62 70 72
or and
t62 t70
Operating phase 2
9/0
Pre-purge
32
After burner time
t01 tmx1 tmx1

C
B
C
B
C
B
C
B
c
k
A/c A/c
e A/c A/c 9
A/c A/c
C
A
30

post purge position
Air stepping motors in

pre-purge position
24
Fuel valve
ON
36 38 40
und und
t30
t34 t36 t38
tv
TSA1
tmx2
tmx1
tmx1
tmx1 tmx3
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
D
D
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
i
i
i
i
c
C
A
A
A
A
A
A
C
A
A
A
A
A
A
c
C
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
r
C
A
A
C
A
A
A
A
A
A
A
B
B
B
B
B
B
B
H
D
9
N
N
N
N
N
N
N
N
2 2 2 2 2 2
N
N
49 4 4 4 4 4 4 4 4
Fan = ON
21 22
und
t21 t22
Safety fuel
valve = ON
Safety
relay = ON
20
k
A
A
t74
74
tn1
3
3
3
Standby
10 12
und
t10
k
A
A
A
A
tmx1
76
Post purge
q
1
Safety phase
01
E
E
m
k
A
A
A
A
t78
78
tn3 5
X10-02: 6
X3-02: 1
X4-01: 3
X4-01: 3
X9-03: 2
X5-02: 1
X5-02: 2
X6-01: 1
X3-01: 1
X4-02
X4-03
X3-01.2
X3-01: 1/2
X6-03: 3
X8-02/-03
X7-01
X7-02
X6-02: 3
Lockout phase
00
TSA2
Shutdown
N
N
H
N
c
A
k
c
tmx2
B
B
B
tmx1
79
X4-01: 2
X3-04: 1
Oil direct ignition
TSA1
Operation
Direct start
Operating phase
Timer-Event-Link
Timer 1
Timer 2
Timer-Event- Link
Fuel switch OIL
Safety circuit
Temperature limit internal
Controller ON
Flame signal
or FGR-Fan-PS
CPI or VP-PS
Low oil press. sw. LOPS
High oil press. sw. HOPS
Start release Oil
Burner fan motor
Ignition
3-way solenoid on APS
Alarm
Safety relay Oil
Fuel valve 1 Oil
Fuel valve 2 Oil
Fuel valve 3 Oil
Magnetic clutch/sep. Pump
tv
Start up
Sequence diagram oil with direct ignition
Fuel
Actuators
Air
83
9
Legend for the sequence diagrams
Signal ON
A
Signal OFF
Reaction if relevant signal to sequence diagram is not given

Jump to operating phase 01, with repetition counter = 0 on to phase 00 otherwise in Ph 12
Jump to operating phase 10
B
C
Stop until completion of Phase max. time (tmx...), then jump to phase 01
With heat demand from controller and parametered direct start jump to phase 79,
otherwise to phase 10
Without valve proving jump to operating phase 70, otherwise to phase 80
Stop until completion of Phase max. time (tmx...), then jump to phase 10
03 s
030 s
03 s

i
With parametered direct start jump to phase 79, otherwise to phase 10
Output: ON
Output: OFF
Input: no influence
1 Depending on parametering with or without LP

2 Depending on parametering short or long pre-ignition time and pump on time
3 Delayed shutdown in TSA1 + TSA2
4 Depending on parametering output as start signal or PS relief valve
5 Depending on parametering Normal/Direct start
6 Follow on phase 24
7 Only with valve proving during commissioning
8 Depending on parametering with or without alarm at start inhibition
9 With parametered continuous running fan
0 Fan remains driven as before
q Depending on parametering with or without extraneous light test in standby
w With deviation during start up follow on phase 10
e With normal venting: Check for ON in phase 10, stop until completion of phase max. time, then jump to phase 01
With continuous running fan: Check for ON in phase 10 and 12, stop until completion of phase max. time, then jump to
phase 01
r If the min. oil pressure switch input has been parametered to Act from ts no check is carried out prior to completion of
TSA 1 time
t If the low gas pressure switch input has been parametered to deactOgp no check is carried out with oil with gas pilot
ignition
z If the output is parametered to DirectCoupl, the safety valve Oil has to be connected. The output is driven together
with the fan and stops 15 s after the fan in time delay.
u If the output is parametered to PS relief, this (output PS relief valve) is inverted logically
i The alarm output can be temporarily deactivated for the current fault
84
9
Assignment times:
Time
Description
t0
t01
t10
t21
t22
t30
t34
t36
t38
t42
t44
t52
t62
t70
t74
t78
t80
t81
t82
t83
tmx1
tmx2
tmx3
TSA1
TSA2
tv
Post-purge lockout setting

MaxTime_SiPhase
MinTimeHomerun
MinTimeStartrelease
FanRunupTime
Prepurgetime part 1
Prepurgetime part 3
MinOnTimeOilPump
PreIgnTime_Gas / Oil
PreIgnTime_Off
IntervalTime 1 Gas / Oil
IntervalTime 2 Gas / Oil
MaxTime low fire
Afterburn time
PostpurgeTime 1 Gas / Oil (tn1)
PostpurgeTime 3 Gas / Oil (tn3)
Valve proving empty time
Leakage test test time atm. pressure
Leakage test filling test
Leakage test test time gas pressure
Max. damper run time
MaxTime start release
MaxTime venting HO Oil
Safety time 1 Gas / Oil
Safety time 2 Gas / Oil
Prepurge time_Gas / Oil
Actuators
In Standby:
The SA can be moved within the permitted
position range, will however, always be driven
to the standby position, and must be in
standby for phase change.
Abbreviations
FGR
CPI
PS
VP
BrnFan
PL or LF
AD
APS
PP
S
SR
STB
TL
PV
Z
Flue gas recirculation

Closed position indicator
Pressure switch
Valve proving
Auxiliary contact burner fan contactor
Low fire position
Air damper
Air pressure switch
Post-purge position / post-purge
Standby
Safety relay
Safety temperature limiter
Temperature guard
Pre-purge position / pre-purge
Ignition position
85
10 O2 sensor
Installing the O2 sensor
DANGER
Electrically isolate the plant

Prior to installation, switch off the mains
switch and the safety switch.
Failure to comply could cause death or
serious injury by electric shock.
The O2 sensor must only be fitted with the relevant

flanges and to the enclosed drawing.
No infiltrated air must enter before, and at least 2 x

diameters of the flue gas ducting after the sensor.
The sensor should be fitted as close as possible after

the flue gas outlet terminal of the appliance, but no
closer than 1 diameter of the flue gas pipe.
During operation, the sensor is heated to

approx. 700C.
DANGER
Sensor position
min.
1x
The sensor must not be fitted vertically from below,

pointing upwards.
The favourable fitting position is vertically from above

or up to 45 angle either side of vertical.
The minimum distance between the inner wall of flue

gas duct and the flue gas sampling outlet hole on the
flange is 10 mm.
1020
Air
up to 45
Installation instruction
Gas tight (sealed)

welding
do not insulate
86
min. 10 mm
10
Electrical connection
The 6 core connection line between the terminal rail X1 of
the O2 module and the sensor is fitted with a screened line
twisted in pairs (3 x 2 x 0.25 mm2).
One side of the screening should be attached to the
mounting plate of the O2 module. There must be no
connection between GND and earth.
The sensor heating L (Q4), N (Q5), PE should be fitted to
the O2 module terminal rail X10 Pin 1, 2, 3 with a minimum
3 x 0.75 mm2.
The line of the sensor heating must be a separate cables.
Outside diameter of the cable = Max. 8 mm.
Connection to O2 module
X10
Mains
O2 module
L (Q4)
N (Q5)
PE
Q5
Q4
GND
U3
G2
M
B2
M
B1
U3
B2
M
B1
L, N, PE:
Supply voltage sensor heating 230V pulsed

(N switching)
U3 :
Temperature compensation 1 A/K relating to

absolute zero, i.e. 273 A corresponds to a
sensor temperature of 0 C
G2 :
Feeder voltage temperature compensation 2

to 10V
B3 / M :
Thermo element 0 to 33 mV
29.1 mV corresponds to approx. 700 C
B1 / M :
Nernst voltage (0 to 700 mV)
Nernst voltage at 700 C sensor temperature

700C
120
100
Nernst voltage [mV]
X1
G2
80
60
40
20
0
0,05
0,1
0,2
0,5
10
20
O2 content [%]
87
11 Frequency converter
If the W-FM 200 is used in connection with a frequency
converter VLT 2800 or VLT 5000 (Danfoss),the
parametering of the frequency converter has to be
checked and if necessary adjusted.
Further information and details relating to the frequency

converter can be found in the manufacturers
documentation.
If a frequency converter (Siemens) fitted directly to the

burner motor is used, parametering of the FC is not
required or indeed possible.
11.1 Programming and display unit frequency converter Series VLT

The programming and display unit allows manual access to
the frequency converter during burner operation or
commissioning.
Furthermore the programming and display unit shows
operating values and is used to program the frequency
converter.
Programming the frequency converter with the W-FM or its
ABE is not possible.
Note Please observe the manufactures installation and
operating instruction for the frequency converter.
Programming and display unit VLT 2800
Six digit LCD display

+/- Buttons
Selection of parameters and value changes
Quick-Menu
Call up menu or return without changes
Change Data
Confirm value changes
LED display of operating conditions
Stop/Reset
Stop motor / reset lockout
Start
Starts the frequency converter
88
11
Programme and display unit VLT 5000
4 line LCD display
24,3% 30,2% 13,8A
50.0 Hz
Menu
Call up of menus for all parameters
Operation
Quick-Menu
Call up of all parameters in the quick menu
Display/Status
Selection of display/change to display mode
OK
Confirmation of value changes
DISPLAY
STATUS
MENU
Cancel
Cancel value changes
Change Data
Changes the parameter selected
CANCEL
OK
+/- Buttons
Selection of parameters and value changes
Arrow buttons
Selection of parameter groups and value changes
LED display of operating conditions
Stop/Reset
Stop motor/reset lockout
JOG
Activate fixed speed / deactivating (parameter 15)
STOP
RESET
JOG
FWD.
REV.
START
FWD./REV.
Change of rotation direction (parameter 16)
Start
Starts the frequency converter
89
11
11.2 parametering the VLT 2800
In connection with the W-FM 200, certain parameters on
the frequency converter have to be checked and set if
necessary.
No.
Description
Value
Unit
019 Mains-On-Mode
automatic restart at mains activation
100 Configuration
speed control with motor slip adjustment
101 Torque reference line
constant torque
xx.yy
kW
to name plate
103 Motor voltage
xx
to name plate
104 Motor frequency
xx
Hz
to name plate
105 Motor current
xx.yy
to name plate
106 Motor speed
xxxx
kW
to name plate
123 Frequency stop function
Hz
activation motor free run if not reached
126 Direct current brake time
sec.
127 Frequency DC brake
Hz
activation of DC brake if exceeded
132 Voltage DC brake
50
brake voltage
133 Voltage increase
no voltage increase
134 Load compensation
80
load reference line
136 Slippage adjustment
0.0
no motor slip adjustment
144 Increase AC brake
1.0
202 Max. frequency
52.5
Hz
upper limit value output frequency
204 Min set point
0.0
Hz
minimum set point input
205 Max. set point
52.5
Hz
maximum set point input
207 Ramp time Open 1
81/152/283
sec.
acceleration time from 0 Hz to nominal frequency
208 Ramp time From 1
81/152/283
sec.
delay time from nominal frequency to 0 Hz
211 Ramp time Jog
81/152/283
sec.
acceleration/delay time fixed speed
212 Ramp time From Quick Stop
81/152/283
sec.
delay time quick stop
Hz
52.5
Hz
102 Motor rating
Meaning
duration for DC brake
128 Thermal motor protection
213 Frequency Jog

226 Warning fmax limit
1 up to size 50
2 on sizes 60 to 70
3 WK burners
90
alternating current brake deactivated
frequency for fixed speed
11
No.
Description
Value
Unit
Meaning
302 Input 18 digital
Start signal from W-FM200 contact X73:1/2
No function, input deactivated
Direct current brake
No function, input deactivated
Recording, reset with W-FM 200
308 Input 53 analogue
0-
set point signal from W-FM200 terminal X73:4
314 Input 60 min. scaling
4.0
Alower set point signal min.
315 Input 60 max. scaling
20
Aupper set point signal max.
318 Function after set point fault
off, function deactivated
319 Output 42 analogue
recorder output 0-20 mA
323 Relay output
38-contacts are switched at alarm
341 Output 46 digital
output reacts at alarm or warning
349 Delay speed comp.
ssystem delay time
400 Brake function
with alternating current brake
405 Type of recording
10
10 automatic restart trials after termination
445 Motor hold switching
Holding the motor
no function, input deactivated
91
11
11.3 Parametriering VLT 5000
In connection with the W-FM 200 certain parameters on
the frequency converter have to be checked and set if
necessary.
No.
Display
Data
Meaning
002 Operating mode
REMOTE
013 Setp. Local Mode
BLOCKED
019 Mains ON mode
AUTO RESTART
Automatic restart when mains switch on
100 Configuration
WITH SLIP COMP.
Speed control with slippage adjustment
101 Torque ref. line
N-CONST-TORQUE
Constant torque
Set nominal rating
as per name plate
Set nominal voltage
as per name plate
Set nominal frequency
as per name plate
105 Motor current
Set nominal current
as per name plate
106 Motor nom. speed
Set nominal speed
as per name plate
102 Motor rating

103 Motor voltage
104 Motor frequency
Remote control
Set point input only with digital inputs from W-FM
113 Load adjust. low
80%
Load compensation in lower speed range
114 Load adjust. high
80%
Load compensation in upper speed range
115 Slip. adjustment
0.0%
no slippage adjustment
122 Stop function
DC BRAKE
active at shutdown
123 Freq. stop function
2Hz
activates motor free run if not reached
124 DC Hold current
0.0%
Off
125 DC Brake current
50%
corresponds to half motor nominal current
126 DC Brake time
2 sec.
Duration DC braking
127 DC br. start freq.
2Hz
activates motor free run brake if exceeded
128 Therm. motor protection

202 Max. frequency
52.5 Hz
Upper limit value output frequency
204 Min set point
0.0 Hz
Minimum set point input
205 Max set point
52.5 Hz
Maximum set point input
207 Ramp Open
181/152/283 sec
Acceleration time 0 Hz to nominal speed
208 Ramp From
181/152/283 sec
Delay time nominal speed to 0 Hz
212 Ramp Q Stop
181/152/283 sec
Delay time quick stop
213 Frequency Jog
0.0 Hz
Frequency for fixed speed
216 f-max limit
52.5 Hz
Warning at speed limit
1 up to size 50
2 on sizes 60 to 70
3 WK burners
92
11
No.
Display
Data
Meaning
NO FUNCTION
NO FUNCTION
STARTS
NO FUNCTION
DC BRAKE
NO FUNCTION
NO FUNCTION
RECORDING
tart signal from W-FM 200 contact X73:1/2

Direct current brake
Rest by W-FM 200
SETPOINT
315 Input 60 scale min
4.0 m
Alower set point signal min.
316 Input 60 scale max
20.0 m
Aupper set point signal max.
OFF
318 Funct. foll. setp. fault
Set point signal from W-FM 200
319 Output 42 d or a
0-I MAX = 0-20 m
321 Output 45 d or a
ALARM
output reacts at alarm
323 Output 1-3 relay
ALARM
Contacts switched at alarm
400 Brake function

405 Recording
445 Hold switching
OFF
10 x AUTOMATIC
ACTIVE
Aanalogue recorder output 0-20 mA
no brake resistance
10 automatic restarts after termination
Holding the motor
93
12 Cause and rectification of faults (fault list)

Faults are displayed alternating as codes and clear text
information. The following fault possibilities are listed in
order of fault code and diagnostic code.
Fault rectification:
Call up fault history - analyse last fault
Determine cause, determine reason
Rectify fault
If necessary, record fault
Display - Fault history

Operating mode
Fault history
1 18.06.99
C:15 D:1
Start No:
Load:25.0
10:35
P:81
123456
Gas
Stepping motor
fault from ECR
C: = Fault code
D: = Diagnostic code
P: = Phase
Fault list
Fault
list
Fault
code
Cause
Recommended measures
01
02
03
04
05
01
0107
0144
01,02
ROM Fault
RAM Fault
Fault at internal data comparison
Synchronisation fault
Fault flame signal booster test
0104
011B
Fault internal hardware test

Fault inputs / outputs
1)
1)
1)
1)
1)
Replace flame sensor
1)
The number of the diagnostic codes shows
which input is faulty.
Neutral conductor may be missing, (or not zero V)
06
10
01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
0E
0F
10
11
12
13
14
15
16
17
18
19
1A
1B
Load controller on/off

Fan contact
Oil operation selection
Gas operation selection
Reset
Pressure switch Oil maximum
Pressure switch Oil minimum
Pressure switch valve proving
Safety valve Oil return signal
Fuel valve 1 Oil return signal
Safety valve Gas return signal
Fuel valve 1 Gas return signal
Safety circuit burner flange
Safety relay return signal
Pressure switch Gas minimum
Pressure switch Gas maximum
Ignition transformer return signal
Fan pressure switch
Start release Oil
Residual oil immediate start
Load controller open
Load controller closed
Start release Gas
The fault could be caused by capacitance loads,

causing longer than 10 ms to reduce the voltage
to 0 Volts before the relay switches off.
Check control wiring
1)
1) If it occurs sporadically improve EMC measures.

If it occurs permanently replace W-FM
94
12
Fault
list
Fault
code
11
15
01
013F
16
17
18
01
02
04
08
10
20
0023
00
01
02
03
04
05
0A
0B
0C
0D
Cause
Short circuit contact return signal network

Stepping motor position or
speed not reached
1)
The diagnostic value is made up of the
faults listed or their combination.
The individual diagnostic codes are added
hexadecimal.
With sporadic occurrences improve EMC measures.
Positioning fault air stepping motor

Positioning fault fuel stepping motor
Positioning fault auxiliary stepping motor 1
Speed not reached
Plausibility fault in ECR
Fault ratio curve air stepping motor
Fault ratio curve fuel stepping motor
Fault ratio curve auxiliary stepping motor 1
Fault ratio curve frequency converter
P-content outside of permissible range
I-content outside of permissible range
Tau outside of permissible range
Calculated O2 set point outside
of permissible range
0E
Calculated O2 min value outside
0F
Calculated O2 ratio value outside
13
Load /point number input of the
ABE outside of permissible range
14
Calculated standardisation
value outside of permissible range
20
With hysteresis compensation, exceeding
the permissible adjustment range
21
Load /point number input of the ABE
outside of permissible range
22
At switch command none
of the def. cases was met
23
At switch command no defined
ECR phase was recognised
0103, 3F Internal communication fault ECR
01
TimeOut at programme run
synchronisation of data transfer
02
TimeOut at data transmission
03
CRC fault at data transfer
3F
Different values detected at
data synchronisation
Invalid curve data
With permanent occurrence, replace relevant

stepping motors (see diagnostic code).
Check if motor is overloaded
The diagnostic code describes the cause
Check ratio curve of relevant motor or FC module
and parameter if necessary.
Check O2 control parameter and adjust if necessary
Check if the values entered are valid.

If necessary repeat setting for O2 control
1)
1)
Check curve data for invalid entries.

For initial commissioning of the unit:
Correct to the valid value range
If previously operating correctly:
Replace defective base unit
1) With sporadic occurrences improve EMC measures.
With permanent occurrence replace W-FM
95
12
Fault
code
19
Diagnostic Cause
code
012F
01
02
04
08
20
1A
01
1B
1C
013F
01
02
1D
04
08
10
20
013F
1E
01
02
04
08
10
20
013F
01
02
04
08
10
20
96
Fault at comparison pot channel A to B.

The diagnostic code shows which motor
is faulty.
Air stepping motor faulty at comparison
pot channel A to B
Active fuel stepping motor faulty
at comparison pot channel A to B
Auxiliary stepping motor 1 faulty
The curve gradient of a partial
curve section is too high
The programming mode remains active

in phase 62 and the set positions
(normal operation) have not been
reached
The diagnostic value is made up of the faults listed
or their combination. The individual diagnostic codes
are added hexadecimal.
With sporadic occurrences, improve EMC
measures.
With permanent occurrence, replace relevant
steppingmotors (see diagnostic code).
Max. gradient between two support points:

- 3.6 per 0.1 % (30s ramp)
- 1.8 per 0.1 % (60s ramp)
- 0.9 per 0.1 % (120s ramp)
Alter load matching of the support point until
the conditions are met.
Curve parametering should be carried out in manual
operation to avoid shutting down the load controller.
However, if the TL reacts this can lead to shutdown.
The value (curve point) currently being changed
can however be locked in Standby or lockout
The relevant ignition positions

have not been parametered.

or their combination. The individual diagnostic
codes are added hexadecimal.
Ignition pos. air stepping motor not param. Set ignition position
Ignition pos. of active fuel stepping motor
not parametered
Ign. pos. auxiliary stepping motor 1 not param.
Ignition pos. FC not parametered

Run time fault stepping motors /

frequency converter

Run time fault air stepping motor
Check motor for mechanical overload.
Run time fault current fuel stepping motor Check supply voltage and fuses.
Run time fault auxiliary stepping motor 1 Drive ramp of the stepping motor must be
Run time fault auxiliary stepping motor 2
parametered ramp.
Run time fault frequency converter
Ramp of the frequency converter must be smaller than the
Run time fault auxiliary stepping motor 3
ramp parameter in the WM-F. Recommendation 20%.
The base unit has detected, that one
or more stepping motors (incl. FC) have
not reached the special position
required for the phase.
Special pos. air stepping motor not reached
Check motor for mechanical overload.
Special pos. current fuel stepping motor Check supply voltage and fuses.
not reached
Spec. pos. auxiliary stepping motor 1 not reached
Spec. pos. FC (speed) not reached

12
Fault
code
1F
Diagnostic Cause
code
0106
Fault detected with FC module
01
02
Fault internal test in FC module

Wrong rotation direction of fan
03
Impulse sequence and length at speed

input different than expected
Nominal speed not reached stable
04
05
21
22
23
24
25
26
27
28
29
06
2A
2B
2C
2D
00, 01
2E
00, 01
2F
30
31
32
33
34
35
36
37
38
39
3A
3B
40
0103
01
02
03
41
Air stepping motor(s) did not reach open

position for standardisation
Fault internal speed test FC module
Safety circuit opened
Temperature guard value exceeded
Extraneous light during start up
Extraneous light during shutdown
No flame end of safety time ts1
Flame failure during operation
Impermissible air pressure signal On
Impermissible air pressure signal Off
Impermissible message On
from fan relay contact
Impermissible message Off
from fan relay contact
Impermissible air pressure signal On
flue gas recirculation
Impermissible air pressure signal Off
flue gas recirculation
Impermissible message On
from valve closing contact
Impermissible message Off
from valve closing contact
Low gas pressure switch has reacted
High gas pressure switch has reacted
Gas pressure switch VP has reacted
Gas pressure switch VP not reacted
Unexpected oil pressure present
Low oil pressure switch has reacted
High oil pressure switch has reacted
No start release oil
No release residual oil immediate start
Low gas programme active
Parameter of safety time faulty
Internal fault at timer1
No burner ID defined
No engineers password defined
Setting internal safety relay
Internal ignition contact setting
With sporadic occurrences:
Check CAN Bus wiring or improve EMC measures.
With permanent occurrence, replace W-FM
Check rotational direction of motor and transmitter disc.

Check rotational direction on FC, correct if necessary
Check installation of transmitter disc and transmitter.
Check distance and connection inductive transmitter.
Check motor is running
Check distance and connection inductive transmitter.
Check motor(s) for mechanical overload.
Check voltage supply to stepping motors
Check gas supply pressure

Check setting gas pressure switch
V1 leaking
V2 leaking
Min. permissible oil pressure not reached
Max. permissible oil pressure exceeded
Check gas supply pressure
Parameter burner ID
Enter engineers password
With sporadic occurrences, improve EMC
measures.
Check wiring of output
97
12
Fault
code
42
43
44
45
46
47
48
98
Diagnostic Cause
code
01FF
Contact setting fault of internal

fuel valve relays
01
02
04
08
10
20
40
80
010D
01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
010A
01
02
03
04
05
06
07
08
09
0A
Safety valve - Oil

Fuel valve V1 - Oil
Fuel valve V2 - Oil
Fuel valve V3 - Oil
Safety valve - Gas
Fuel valve V1 - Gas
Fuel valve V2 - Gas
Fuel valve V3 - Gas
Fault during plausibility check
No fuel selected
No def. fuel train parametered
Variable train not defined
Variable fuel not defined
Undefined mode of operation with LC
Pre-purge time gas too short
Pre-purge time oil too short
Oil Safety time 1 too long
Gas Safety time 1 too long
Ignition - Off - Time > ts1 Gas
Ignition - Off - Time > ts1 Oil
Oil Safety time 2 too long
Gas Safety time 2 too long
Deactivated inputs connected
Controller input to X62
Activate input or connect nothing
Air pressure switch input X3-02
Brn Fan / FGR air pressure switch X4-01:3
Low gas pressure switch terminal X9-03:4
High gas pressure switch terminal X9-03:3
Low oil pressure switch terminal X5-01
High oil pressure switch terminal X5-02
Start signal Oil input X6-01:1/2
0107
01
02
03
04
05
06
07

or their combination. The individual diagnostic codes
are added hexadecimal.
Check wiring of output
Residual Oil immediate start input X6-01:3/4
Start signal Gas input X7-03

At STB test activated a controlled
shutdown was carried out
A programme stop has been activated
Phase 24: Pre-purge
Phase 32: Pre-purge for FGR
Phase 36: Ignition positions
Phase 44: End first safety time
Phase 52: End second safety time
Phase 72: Post-purge position
Phase 76: Post-purge position FGR
Start release Gas = Off
1 sensor operation parametered,
but 2 flame signals present
If the programme stop (see Ch. 9.6.1) is no longer

required, deactivate it.
12
Fault
code
Diagnostic Cause
code
50
51
52
53
58
59
5A
5B
5C
5D
5E
5F
60
61
70
0007
0007
0103
01
0123
0104
71
72
80
81
82
83
84
85
86
87
0104
0103
0103
0103
0103
0103
0103
0103
0103
88
90
91
92
93
94
95
96
97
98
0105
01
02
03
04
01
99
9A
9B
01, 02
Fault in button value check

Time block overrun
Stack fault
Faulty reset condition
Parameter setting is incorrect
Backup restore was carried out
Internal fault
Internal fault
Internal fault
Internal fault
Fault at rectification of
lockout information
Manual lockout with contact
1)
Reset unit
If this fault occurred during parametering:
check parameter last changed for plausibility.
If reset does not achieve faultless condition:
Restore parameters from ABE
Otherwise replace defective base unit.
1)
The lockout by the external contact

is cancelled by re-activating.
Plausibility fault at fault entry
1)
Impermissible cond. auxiliary stepping motor3 With sporadic occurrences, improve EMC measures.
Impermissible condition air stepping motor
Impermissible con. gas stepping motor (Oil)
With permanent occurrence, replace relevant motor.
Impermissible condition oil stepping motor
Impermissible cond. auxiliary stepping motor1
Impermissible cond. auxiliary stepping motor2
Impermissible condition of internal LC

Impermissible condition of ABE
Plausibility fault
Non defined fault stepping motors
Non defined fault load controller
Non defined fault ABE
Non defined fault FC module
Non defined fault O2 module
ROM-CRC fault auxiliary stepping motor3
ROM-CRC fault air stepping motor
ROM-CRC fault gas stepping motor (oil)
ROM-CRC fault oil stepping motor
ROM-CRC fault load controller
ROM-CRC fault ABE
Multiple components with the same
address on the CAN Bus
CAN is in BusOff
CAN Warning Level
CAN Queue overrun
1)
With sporadic occurrences,
improve EMC measures.
With permanent occurrence, replace ABE
With permanent occurrence replace defective unit
(see diagnostic code) or base unit.
Check addressing of connected components

and correct if necessary.
Check CAN wiring
1)
1) With sporadic occurrences,
99
12
Fault
code
A0
A1
A2
A3
A4
A5
Diagnostic Cause
code
011F
011F
011F
011F
011F
011F
01
02
04
05
07
08
09
0C
0D
0E
10
11
12
13
15
16
17
18
19
1B
A6
1E
1F
10FF
10
12
13
14
15
16
17
18
22
3032
33
343B
40
4143
Auxiliary stepping motor3 has signalled fault

Air stepping motor has signalled fault
Gas stepping motor has signalled fault
Oil stepping motor has signalled fault
CRC fault at ROM test
CRC fault at RAM test
Fault in button value test
Time block overrun
Sync fault or CRC fault
Revolution counter
Fault at stack test
Temperature warning and shutdown
Wrong rotation direction
Ramp time for stretch too small
Timeout at AD change
Fault at ADC test
Fault at AD change
Stepping motor is outside of the valid
degree of angle (0-90)
CAN fault
CRC fault of one parameter section
Section was opened too long
Section is damaged
Invalid access to parameter
Fault at copying parameter section
Invalid setting in drive order

Plausibility fault internal
Internal LC has signalled fault
No actual value increase
Invalid XP identified
Invalid TN identified
TV larger than identification time
Invalid TV identified
Timeout during observation time
With permanent occurrence,
replace the relevant motor.
Check housing temperature (max. 60 C)
Match ramp time to slowest motor

Reduce spanning between special positions
Check setting range (0-90)

Check CAN wiring
Reset unit
Otherwise, replace defective base unit.
Check special positions are within valid range
Type of fault: see diagnostic code
1)
Cold start thermal shock protection is active
Timeout during adaption load

Temp controller Set point larger limit value
Internal fault load controller
Invalid CRC when reading a section
Reset unit, poss. repeat Backup Restore
1)
Section open too long
Reset unit. If this fault occurred during parametering:
Restore parameters from ABE.
1)
1) With sporadic occurrences, improve EMC measures.
100
12
Fault
code
Diagnostic Cause
code
44
45
46
Section was set to ABORT

Section was set to RESTO
Section has invalid status
4A4E
50
CAN fault
PT 100 sensor short circuit
on input X60:1/4
PT 100 sensor break
on input X60:1/4
Break in compensation line
on input X60:2/4
PT 1000 sensor short circuit
on input X60:3/4
PT 1000 sensor break
on input X60:3/4
Ni 1000 sensor short circuit
on input X60:3/4
Ni 1000 sensor break
on input X60:3/4
Over voltage on input X61
Break or short circuit
on input X61
Over voltage on input X62
Break or short circuit
on input X62
51
52
53
54
55
56
57
58
59
5A
606F
70
71
72
73
74
75
76
77
78
79
7A
7B
7C
7D
7E
7F
80A6
A7
B0FF
Reset unit
If this fault occurred during parametering: check parameter last changed for plausibility. If reset does not
achieve faultless condition: Restore parameters from ABE
1)
Check wiring and sensor
1)
Measurement value variation, PT 100 sensor Check wiring of input
Measurement value variation, PT 100 line
Measurement value variation, PT 1000
Measurement value variation, PWM
1)
Measurement value variation, U input X61 Check wiring of input
Measurement value variation, I input X61 Check signal for ripple voltage
Measurement value variation, U input X62
Measurement value variation, I input X62
Over voltage or wrong polarity
Check wiring of input
PT 100 sensor, input X60
Over voltage or wrong polarity PWM
1)
Check wiring of input
U measurement input X61
Check input voltage or current
I measurement input X61
U measurement input X62
I measurement input X62
1)
Impermissible selection for the additional A pressure or temperature sensor must
sensor
be fitted to X61 (see Ch. 9.8.3 and 9.8.4)
1)
With permanent occurrence replace W-FM
101
12
Fault
code
A7
Diagnotic Cause
code
018A
The ABE signals faults.

Type of fault, see diagnostic code
With sporadic occurrences, improve EMC measures.
With permanent occurrence, replace ABE
A9
01 08
09
0A
0B
0C
0D
0E
15 1A
1B
1C28
30
38
40
888A
011F
0109
0A
0C
0D
0E
15 F
16
17
18
19
1B
AB
1E
1F
013F
010A
10
12
13
15
16
171B
20
21
22
23
Internal fault ABE

Fault signal Emergency-Off Function ABE
Internal fault ABE
Service message through burner starts
Fault parameter backup
Fuel changeover from oil to gas
Fuel change over from gas to oil
Internal fault ABE
Fault during copying parameter section
Interner Fehler ABE
Fault during eBus communication
Interface mode could not be stopped
Parameter fault PC Tool
Internal fault ABE
FC module has signalled a fault
Internal fault FC module
Poss. fault on line to speed
transmitter
Frequency converter has initiated fault
FC module could not control speed
difference within its control limit
Fault during speed calculation test

Interrupted CAN Bus transmission
CRC fault of a parameter section

Section was open too long
Section has been destroyed
Invalid entries in drive order
Plausibility fault internal
O2 module has signalled a fault
Internal fault O2 module
Nernst voltage QGO sensor (B1/M)
Voltage thermo element (B2/M)
Voltage compensation element (G2/U3)
Supply air sensor out of range
Flue gas sensor out of range
Internal fault O2 module during test phase
Temperature of O2 sensor too low
Temperature of O2 sensor too high
Fault during calculation test
Internal resistance of sensor is smaller
5 Ohm or larger 150 Ohm

102
Carry out service, reset start counter

Change to menu Settings Gas
Change to menu Settings Oil
Reset unit, if necessary repeat parameter backup
1)
Check cabling, use screened
1)
Read fault codes of frequency converter
Check if current interfaces on frequency converter
and FC module are set the same (0/4 to 20 mA).
Carry out speed standardisation incl.
burner adjustment (fuel / air ratio)
1)
With sporadic occurrence check CAN Bus wiring,
improve EMC measures
Check closed resistance, correct if necessary
Reset unit
Check special positions for valid range
1)
2)
Check connection (poling, short circuit, break)
Check connection (short circuit, break)

Check ambient temperature (-20 C to +400 C)
2)
Check heating start up O2 sensor (Q4/Q5)
Check QGO temperature
2)
Check connection (poling, short circuit)
Replace O2 sensor
12
Fault
code
Diagnostic Cause
code
24
25
24
B0
B1
B5
25
31
32
33
34
38
3E
3F
01, 02
01
01
01
02
03
04
05
06
BA
BF
07
01
C5
012F
D1
D3
E1
E3
F0
F1
01
02
04
08
10
20
0103
0103
0107
Reaction time O2 sensor more than 5 s
Check position of O2 sensor

Check soiling of O2 sensor
O2 sensor
Faulty O2 sensor test
Check variation of O2 value
Reaction time of O2 sensor more than 5 s Check position of O2 sensor
Check soiling of O2 sensor
O2 sensor
Faulty O2 sensor test
Check variation of O2 value
CRC fault of a parameter section
Reset unit
Section was open too long
Section has been corrupted
Invalid external entry
Plausibility internal fault
2)
Fault during testing port outputs
1)
Fault during short circuit testing
1)
from inputs to outputs
Fault during O2 guarding
1)
O2 min value not reached
Check settings of ratio curve
Increase differential O2 set point to O2 min value
Invalid O2 min value
Define all O2 min values
Invalid O2 set point
Define all O2 set points
Adaption fault point 2 or at 100%
Repeat standardisation at this point (Ch. 9.7.1)
No valid O2 actual value > = 3 s
Check connection O2 module and O2 sensor
Air oxygen content at pre-purge
Increase pre-purge time
not achieved
Replace O2 sensor
O2 value during operation above 15%
Check installation and connection O2 sensor
Test O2 sensor not successful
1)
Fault in connection with O2 control
In the fault history immediately prior to fault BF
or O2 guard
the reason for switch off can be read
ABE has detected old versions during the The diagnostic value is made up of the faults
version comparison of individual units
listed or their combination. The individual diagnostic
Software version of LC not current
Prior to replacing, any units switch on the system
Software version of ABE not current
and wait for approx. 1 min. (until the display parameters
Software version of stepping motor(s) not current are being updated disappears when entering the
Software version of FC module not current parameter level). Then reset. If the fault still persists,
Software version of O2 module not current replace the relevant unit.
Software version of O2 module not current
Impermissible condition frequency converter 1)
Impermissible condition O2 module
1)
ROM - CRC fault in FC module
1)
ROM - CRC fault in O2 module
1)
Plausibility at interpolation calculation
1)
Fault during pre-control calculation
Check curve setting
Check setting of fuel parameter depending
on the fuel selected


103
12
Fault
code
F2
Diagnostic Cause
code
070A
07
08
0A
F3
104
01
Wrong temperature values from

O2 module during calculation of
air load change
O2 module transmitted invalid
value
Flue gas temperature outside of
permitted value range
QGO sensor not heated
sufficiently
The control algorithm is missing
the PID parameters
Increase permitted flue gas temperature

Wait until sensor reaches operating temperature
Check control parameters
13 Maintenance
13
13.1 Safety information for maintenance
DANGER
Failure to carry out maintenance and service

work properly can have severe consequences, including the loss of life. Pay close
attention to the following safety notes.
Detailed information and instructions for maintenance can

be found in the installation and operating instructions of
the burner.
Qualified personnel
Only qualified and experienced personnel must carry out
maintenance and service work.
Endangering operational safety

Maintenance work on the following parts may only be
carried out by the manufacturer or their appointed agent
on the individual components.
Combustion manager
Stepping motors
Flame sensor
Gas pressure switch
Air pressure switch
Oil pressure switch
Solenoid valves
Prior to all maintenance and service work:

1. Electrically isolate the equipment
2. Close all fuel shut off devices
After all maintenance and service work:
1. Function test.
2. Check flue gas analysis i.e. CO2 / O2 / CO values,
smoke No.
3. Complete a test sheet.
13.2 Maintenance plan

The operator should ensure that combustion plant is
serviced at least
once a year by an agent of the supplier or other suitably
qualified person.
During this service all system components with high wear
and tear, or components with a specific life span should be
replaced. Notes to be made of such exchanges.
105
14 Technical data
14.1 Combustion manager W-FM
Mains voltage
AC 230V -15% / +10%
Transformer AGG5,220 - primary

- secondary
Mains frequency
AC 230 V
2 x AC 12V
Ambient conditions for all components:
Transport
- climatic conditions
- temperature ranges
- humidity
DIN EN 60 721-3-2
Class 2K2
-20 to + 70 C
< 95 % r. h.
Operation
- climatic conditions
- temperature ranges
- humidity
DIN EN 60 721-3-3
Class 3K5
-20 to + 60 C
< 95 % r. h.
Mechanical requirements
50...60 Hz 6%
Consumption
< 30W
Type of protection housing

Protection class I
IP00, IEC 529

with parts according
to II and III to DIN EN 60 730-1
Mains pre-fusing (external)max. 16 AT

Unit fusing (internal)
6.3 AT (IEC 127 2 / 5)
Dew point, freezing, water ingress not permitted

CE Conformity
To the guidelines of the EU

Electromagnetic compatibility
EMC 89 / 336 EU incl. 92 / 31 EU
Mains supply input currentinstallation specific

Individual contact loading:
Nominal voltage
AC 230V + 10% / - 15%, 50-60 Hz
- Fan motor contactor
max. 1 A
- Ignition transformer
2A
- Fuel valves Gas
2A
- Fuel valves oil
1A
- Oil pump / solenoid valve
max. 2 A
- LP test valve
max. 0.5 A
- Alarm output
1A
- Ratings factor
cos > 0.4
Interference transmission
Interference fastness
To EN 55022
To IEC 1000-4-3
Housing dimension
Input currents/input voltages
200
UeMaxUmains + 10%
UeMinUmains - 15%
leMax 1.5 mA peak
leMin 0.7 mA peak
182
Signal inputs
Class 2M2
Total contact loading (Safety circuit)

Nominal load
Unit input current
AC 230V + 10% / - 15%, 50-60 Hz

max. 5 A
Cable lengths
CAN Bus total length
CAN Bus special cable
Cable diameters
max. 100 m (100pF/m)

max. 100 m
Weishaupt No. 743 192
min. 0.75 mm2
(multi-core to VDE 0100)
The cable diameters of the mains supply (L, N, PE) and the
safety circuit (STB, low water, etc.) must be selected for
the nominal currents relative to the selected external prefusing.
The cable diameters of the remaining conductors should
be dimensioned in relative to the internal unit fusing (max.
6.3 AT).
Internal fusing: F1
F
F3
6.3 AT (IEC 127 2 / 5)

24 AT(IEC 127 2 / 5)
4 AT(IEC 127 2 / 5)
Low-voltage transformer
When the W-FM is fitted into a control panel, the burner
must also be fitted with a low-volt transformer for the
control voltage to the stepping motors.
106
232
250
82,3
14
14.2 Stepping motors SQM45.../48...
Supply voltage
AC 2 x 12 V
Protection class
Install low voltage cables with safe

separation from mains voltages
Consumption - SQM45...
- SQM48...
9...15VA
26...34 VA
Angular adjustment
max. 90 <
Installation
optional
Degree of protection to EN 60529 IP54 with relevant

version of cable entry
Torque: - SQM45...
- SQM48...
up to 3 Nm
up to 20 Nm
Repeat accuracy
0.2
Rotation direction
Cable connection
The connection of the screened Bus cable is via plug
screw terminal Rast 3.5. The two connection sockets
(x1, X2) on the stepping motor have the same value.
Cable and cable screening
Only special cable (Weishaupt No. 743 192) may be used.
Cable screening must be connected to the circuit board
with the flat plug provided.
Housing cover
The housing cover must only be removed for the short
period during wiring and addressing. Ensure dirt particles
cannot enter the internals of the stepping motor.
The stepping motor contains a printed circuit board with
static sensitive components. Its surface is protected
against direct contact by a protective cover. Contact with
the underside of the circuit board should be avoided.
The protective cover must not be removed!
Can be set in W-FM
Run times: - SQM45...

- SQM48...
10 to 120 s
30 to 120 s
Weight: - SQM45...
- SQM48...
approx. 1.0 kg
approx. 1.6 kg
Dimensions
90
,4
76
116
15
2
12
,0
3N9
122
Groove for
Woodruff key
3 x 3.7 DIN 6888
87
137
25
10 h8
16
SQM 45
41
+0
33
+0,1
2,5 0
50
7814m01
Prepared for
self tapping screws
M5, 10mm deep,
to DIN 7500
+0,1
0
P9
+0,1
0
25,5
2 x M16x1,5
1,9
47
18
Groove for parallel

key 5 x 28
36
SQM 48
39
28
14 h8
107
14
14.3 Flame supervision
QRI
The infrared flame sensor QRI... has the following
characteristics:
Infrared flame sensor with IR sensitive sensor for gas
and oil flames
Integrated flame signal amplifier
Self checking of flame signal for continuous run
For front or side (90) viewing
Fitted to burner body with flange and clamp
Supply voltage: - Operation
- TestDC 21 V + 5%
Signal voltage:
Range
minimum
DC 14 V + 5%
DC 0...5V
DC 3.5 V; Display flame approx. 50%
Consumption
< 0.5 W
Type of protection
Protection class
IP54
II
Length of sensor connection cable

Length of additional sensor line
Installation optional
Vibration to IEC 68-2-6
Weight with cable
max. 1.8 m
max. 100 m
max. 1g / 10...500 Hz
approx. 0.175 kg
Ionisation electrode
Flame supervision with ionisation electrode for gas
operation is suitable for continuous run.
Idle voltage
approx. Umains
Short circuit voltage
max. 0.5mA (AC)
Sensor current
minimum
6 A (DC); display flame approx. 50%
maximum
85 A (DC); display flame approx. 100%
Sensor line length
max. 100m
(core-ground 100 pF (/m)
Note: With increased sensor line (length) the current at

the sensor electrode decreases. For longer line
lengths where very high Ohmic values are
probable, the use of a low capacity sensor line (i.e.
low-loss ignition cable) may be necessary.
108
QRI flame sensor
bl blue wire = reference

br brown wire = supply conductor
sw black wire = signal conductor
Z Additional conductor
14
14.4 Display and operating unit (ABE)
Supply voltage via Bus cable
AC 12 V
Installation
optional
Type of protection to EN 60529

(Viewing side in installed condition)
Ambient conditions
Dimensions
IP54
see basic unit (Ch. 14.1)
Door cut-out for panel mounting

Height 12,5 1 mm
Width90.5 1 mm
Depth (within panel)
Free space for connection cable (below the unit)
Cable - line length
Only original -weishaupt- CAN-BUS cable
(order No. 743 192) must be used.
25 mm
50 mm
max. 100 m
109
110
Notizen
111
Weishaupt products
and service
Max Weishaupt GmbH

D-88475 Schwendi
Find Weishaupt adresses
and telephone numbers
on www.weishaupt.de
Print No.. 83054802, June 2004
Printed in Germany
All rights reserved
Oil, gas and dual fuel burners types W and WG/WGL

up to 570 kW
They are used mainly in houses and small buildings.
Advantages: fully automatic, reliable operation, individual
components easily accessible, easy to service, quiet operation.
Oil, gas and dual fuel burners types Monarch

R, G, GL, RGL up to 10.900 kW
These are used on all types and sizes of central heating
plant. The basic model which has proved successful over
many years is the basis for a variety of versions. These
burners have founded the outstanding reputation of
Weishaupt products.
Oil, gas and dual fuel burners types WK

up to 17.500 kW
WK types are decidedly industrial burners.
Advantages: Built to the modular system, load dependent
variable combustion head, sliding two stage or modulating
operation, easy to service.
Weishaupt control panels, the proven complement to

Weishaupt burners
Weishaupt burners and Weishaupt control panels form
the ideal unit, a combination which has already proved
successful in hundreds of thousands of combustion
installations. The advantages: Cost saving during planning,
installation, servicing and guarantee work. The responsibility
belongs to one manufacturer.
Product and service are the complete

Weishaupt achievement
An extensive service organisation guarantees Weishaupt
customers the greatest possible reliability. In addition
our customers are looked after by heating firms who have
been working with Weishaupt for many years.
info
Information on regulators
Regulators for gas and dual fuel burners with gas supply pressures up to 4 bar
Description
General
The gas pressure regulators fitted to all gas and dual
fuel burners are subject to very high dynamic
demands, owing to the speed of switching of the
burners gas valves and the small volumes of gas
between the gas regulator and the burners safety
shut off valve.
Pressure regulators with safety assemblies are also

tested and this technical manual forms part of the
test report. If other units are used the burner can not
be appended with the CE mark.
Excess pressure increase is possible if the gas

pressure regulator supplies an excess outlet
pressure due to faulty operation, or if an SAV does
not close its seat and leakage via the seat occurs.
The pressure regulators must be fitted to the burner

as part of the gas valve train.
The gas pressure regulators in this manual are direct

acting units and are in accordance with EN 676
Forced Draught Gas Burners
Capacity, operation and safety can only be ensured if

the correct units for the burners are used.
If the set pressure is exceeded the valve opens

against the closing spring. Once the excess pressure
has decreased the SBV closes automatically. A vent
line to atmosphere should be provided to ensure that
any internal gas leakage can be vented safely. By
setting the vent pressure of the SBV below the
tripping set point of the SAV, it is possible to make
the SBV respond first, and only with a further
pressure increase will the SAV then trip.
The opening and closing times of the burners safety

valves are short, so the gas pressure regulators need
to react quickly to this, as well as burner load
changes during operation. They must also react to an
emergency shut off of the burner from full load
operation. In these cases the safety shut off valve is
usually activated.
The correct installation of the pressure regulators and
safety equipment with their associated impulse lines
ensures trouble free operation. The impulse lines are
fitted and dimensioned to ensure correct function,
and thus ensure the required reaction speed of the
units.
Only the breather and blow off lines have to be fitted
to the installation. Relevant guidelines can be found
in the Installation notes section.
This group of regulators is made to suit the DVGW
regulations, however, some of the regulations do not
apply to burner installations. Here, the problem with
back pressure does not exist. On burner installations,
the outlet pressure for operating and shut down
mode Pa is permitted, and is equal to the required
pressure of the plant.
The units described in this brochure are designed

with maximum inlet pressures: see table.
Refer to DVGW work sheets for partially pre-adjusted
high gas pressure regulators. Gas pressures in
excess of 4 bar make particular demands on space,
installation and equipment, such that their use in
boiler rooms is possible only in very limited
circumstances. Consequently, boiler rooms do not
generally have supply pressures greater than 4 bar.
The entire Weishaupt burner programme is covered,

and the connections to the burner valve trains are of
the correct size.
Purpose of the SAV safety shut off valve

Safety shut off valves serve as a primary safeguard
against excess pressure and gas throughput. The
SAV shuts off the gas supply if its set pressure has
been reached. During normal operation this is open.
The safety shut off valve must not reopen
automatically. Resetting must be carried out
manually.
Contrary to some instructions, which suggest that

installations having a main service pressure regulator
fitted do not then need each appliance to have its
own individual regulator, each burner must in fact be
fitted with one of the regulators detailed here. Mains
supply gas pressure regulators have specific
functions, which are different to those required for
burner operation. Besides which, ratings related
pressure deviations will occur. For example, the gas
throughput changes between partial and full load.
The commissioning engineer familiar with the burner
regulators has immediate access to setting gas
pressures required for each individual burners
requirements.
Burner components and type testing
The standard for forced draught gas burners
stipulaes that the burner must be treated as a single
unit. This operational unit includes all gas side and air
side equipment, and the burners are tested as such.
With types 06/1 to 09/1 and 1-5/1 (type 133...,

233..., 244...) the SAV and the SBV form one unit in
the gas pressure regulating assembly.
With gas inlet pressures above 0.3 bar, the gas

pressure is further safeguarded with SAV and SBV
safety assemblies. These also protect the rest of the
gas valve train from pressures in excess of the
permitted maxima.
Purpose of the gas pressure regulator
Gas pressure regulators have the purpose of
maintaining the outlet gas pressure for every burner
load point, irrespective of the gas inlet pressure and
throughput.
The regulators are designed for burner operation and

should not be used as a main service pressure
regulating station. On installations which operate
more than one burner, each burner should be fitted
with its own regulator.
The SBV is fitted downstream of the gas pressure

regulator.
Safeguard against excess gas throughput

The gas pressure regulator ensures a virtually
constant gas pressure to the burner across all load
points.
Matched to the Weishaupt burner programme

The gas pressure regulators and safety assemblies
covered in this brochure are specially matched to
Weishaupt gas burners. Outlet gas pressures of 200,
140, 100, 50 and 20 mbar are catered for. Operating
pressures above and below these can be set by
spring adjustment. The safety assemblies are factory
preset, for the values see Technical Data.
The pre-assembled sets have been individually tested

for soundness and operation. These tests must be
repeated during commissioning and servicing.
Maximum inlet pressures

Supply pressures of up 0.3 bar are classed as a low
pressure supplies, whereas supply pressures above
0.3 bar are classed as a medium or high pressure
supplies.
The gas regulator closes tightly if the outlet pressure

exceeds the set value, or under zero flow conditions.
The safety shut off valve forms part of the relevant

gas pressure regulator. Via an impulse-line
the SAV senses the outlet pressure from the
pressure regulator section, and if this pressure
exceeds the set value of the SAV, the SAV shuts off
the flow of gas entering the gas-train.
Setting and operations checks form part of the
commissioning. This includes checking the closing
procedure, i.e. if it functions correctly.
Contents
Page
Description
Construction
High gas supply pressure diagram
Weishaupt gas filter and ball valve

pressure loss chart
Weishaupt pressure regulators

types 06/1 to 9/1 and 1/1 to 5/1
with safety assemblies
Selection chart
The set point is determined on site and depends on

the pressure at which the gas pressure regulator
shuts off. The set point must not be higher than the
maximum inlet pressure of the valve trains.

types 5/1 to 9/1
Please note the setting advice given at the end of this

document.
Example of a high pressure gas supply
12
Connection parts
13
Purpose of the SBV safety relief valve

Safety relief valves are incorporated as an additional
safety device. If internal gas leakage (pressure-creep)
is detected, e.g. if the gas pressure regulator does
not close its seat, the safety relief valve vents the
excess pressure to atmosphere.
10
Installation examples and notes
14
Notes on adjustment
15
Dimensions
16
Construction
Pressure regulator, types 06/1 to 09/1
Pressure regulator, type 5/1 25/50
Types 1/1 to 4/1
Type 5/1
Type 8/1 80/80
Pressure regulator, type 9 100/100
High gas pressure supply:

Two burners, each with a pressure
regulator with safety assemblies
Pressure regulator with

safety assemblies
Supply
line
Pressure regulator with

safety assemblies
The burners are each supplied with a pressure

regulator set , which is in accordance with DVGW
worksheet G 490.
In many cases a mains regulator station is connected
upstream, to reduce a supply pressure of between 4
and 100 bar to below 4 bar, at which the regulators
described here can be used on the burners.
Legend
1 Ball vlave
2 Gas filter
3 Pressure gauge with push button valve
4 Safety shut off valve(SAV)
5 Pressure regulator
6 Safety relief valve (SBV)
7 Gas pressure switch
8 Valve proving
9 Double solenoid valve (DMV, up to DN 125)
10 Ignition gas solenoid valve
11 Gas butterfly valve
8 10 11
8 10 11
Burner 1
Burner 2
Weishaupt gas filter and ball valve

pressure loss chart
Pressure loss p [mbar] at inlet pressure of (see below)

50
20
10
9
8
7
6
1.5
1,5
2
2
1.5
1,5
1.5
1,5
0.5
0,5
1.5
1,5
1
1
mb
50
30
mb
0
50
r
0
1,
ba
r
0
2,
ba
r
ba
0
3,
ar
ar
0,5
0.5
25
125
DN
15
0
DN
100
1.5
1,5
DN
10
9
8
7
6
65
DN
80
5
3
2
15
50
10
9
8
7
6
20
15
DN
15
30
DN
40
20
10
9
8
7
6
50
40
30
15
10
9
8
7
6
50
30
20
DN
15
40
40
20
DN
30
Inlet pressure pe
60
70
90
80 100
150 200
Flow rate Vn [m3/h]
300
400 500 700 900

600 800 1000
1500 2000
3000 4000
5000
Natural Gas E, Hu,n = 10.35 kWh/m3, d = 0.606

Natural Gas LL, Hu,n = 8.83 kWh/m3, d = 0.641
Please note:
Gas filter and ball valve must be selected to not
exceed a pressure loss of approx. 50 mbar.
Conversion of LPG, Towns Gas etc. to equivalent Natural Gas throughputs:
Up to this value the admissible flow velocity is not

exceeded and the filtration will be satisfactory. The
nominal diameter selected should be the same or
larger than the inlet nominal diameter of the high
pressure regulator.
VGas
= QBr /Hu,Gas
=
dGas /dNat Gas
Note:
The pressure loss of the gas filter and ball valve has
been included in the graph.
Examples:
VNat Gas = VGas x f
=
dGas /0.641
Gas type
Cal. value Hu
kWh/m3n
Density
kg/m3
Relative
density d
Correction
factor f
Propane
Butane
Towns Gas 1
Towns Gas 2
Towns Gas 3
Towns Gas 4
25.89
34.39
4.89
4.30
6.40
4.20
2.011
2.708
0.513
0.624
1.060
0.801
1.555
2.094
0.397
0.483
0.820
0.620
1.557
1.807
0.787
0.868
1.131
0.967
Application:
Burner rating
Value on Natural Gas axis
QBr
1500 kW, Propane
VPropane =
1500 / 25.89 = 57.9 m3n /h
VNat Gas =
57.9 x 1.557 = 90.1 m3n /h

5

Types 06/1 to 09/1 and 1/1 to 5/1
Technical Data
Weishaupt
type
Pressure
regulator
type
DN
06/1
07/1
133-5-72
133-5-72
25
25
Orifice
mm
inch
3.0
4.7
/8
/16
max. inlet
pressure
bar
Outlet
pressure
mbar
SAV
spring
colour
SAV
setting
range mbar
Product
ID number
Approx
weight
kg
Order No.
4.0
4.0
30 70
30 70
green
green
140 450
140 450
CE-0085 AQ 1090
CE-0085 AQ 1090
15
15
151 336 2666/0

151 336 2667/0
3.0
1.5
30 70
30 70
green
green
140 450
140 450
CE-0085 AQ 1090
CE-0085 AQ 1090
15
15
151 336 2646/0

151 336 2647/0
4.0
4.0
70 140
70 140
green
green
140 450
140 450
CE-0085 AQ 1092
CE-0085 AQ 1092
27
27
151 336 2648/0

151 336 2649/0
08/1
09/1
133-5-72
133-5-72
25
25
6.3
12.5
1/1
2/1
233-12-5-72
233-12-5-72
50
50
10
12.5
3/1
4/1
233-12-5-72
233-12-5-72
50
50
20
25
/4
1
2.5
1.0
70 140
70 140
green
green
140 450
140 450
CE-0085 AQ 1092
CE-0085 AQ 1092
27
27
151 336 2650/0

151 336 2651/0
5/1
244-12-5-72
50
27.5
4.0
70 140
green
140 450
CE-0085 AQ 1094
31
151 336 2652/0
/4
/2
/8
/2
See Print No. 1727 for regulators with safety diaphragms for connection without breather and vent lines
Outlet pressure springs and labels

Type
Outlet pressure
mbar
Colour
Order No.
Label
Order No.
06/1 to 09/1
06/1 to 09/1
06/1 to 09/1
06/1 to 09/1
06/1 to 09/1
12 20
15 35
30 70
50 140
100 210
blue
green
orange
black/white
silver
490 031
490 032
490 033
490 030
490 029
201 000 0810/7

201 000 0811/7
201 000 0812/7
201 000 0813/7
201 000 0815/7
1/1-5/1
1/1-5/1
1/1-5/1
1/1 -5/1
15 35
30 70
70 140
100 210
green
orange
black
silver
490 085
490 086
490 087
490 088
201 000 0811/7

201 000 0812/7
201 000 0814/7
201 000 0815/7
Legend to page 7
1 Cover screw
3 Regulator spring
4 Adjusting screw
5 Sealing cap
6 Diaphragm
7 Breather port
8 Breather line connection
9 Connection section
10 Inlet and outlet pressure gauge
with push button valve
11 Control orifice
11a Impulse line (SAV)
12 SAV spring
13 SAV measuring mechanism
14 Valve adjusting rod
15 Cover cap
16 Diaphragm casing
16a Impulse line
(pressure regulator)
17 SBV safety relief valve
18 Diaphragm support
19 Lever system
20 Valve stem
21 Flange connection
22 Cotter pin
23 Valve disc
24 Orifice
25 SAV valve disc
26 Flange connection
27 Blocking spring
28 SAV safety shut off valve
29 Operating stem
Function of the pressure regulator

The diaphragm (6) of the pressure regulator is
loaded with a spring (3) and transfers its movements
via a lever system (19) to the valve disc (23). The
level of outlet pressure is achieved by an appropriate
spring load.
Function of the SAV safety shut off valve

If damage occurs to the orifice (24), or if the lever
rods (19) jam, the pressure in the diaphragm area
(16) and behind the orifice (24) can rise only until the
safety shut off valve responds, thus interrupting the
gas supply.
Without gas pressure the regulator is open, i.e. the

spring tension presses the diaphragm (6) and the
lever system (19) downwards so that the valve disc
(23) is raised from the orifice (24). As the gas flow is
released, the gas flows through the orifice (24). This
allows the pressure to increase and produces a force
on the diaphragm (6) counter acting the spring
tension. If the resulting force of gas pressure
exceeds the adjusted spring loading, the lever
system (19) is raised by the diaphragm (6) and the
valve disc (23) starts to constrict the orifice (24),
thus throttling the gas flow and terminating the
pressure increase. If, due to gas reduction the gas
pressure behind the orifice and consequently in the
diaphragm casing (16) drops, the valve disc (23) is
opened by the force of the spring.
The SAVs measuring mechanism (13) is connected

to a spring loaded operating stem (29) and transfers
its movement to the valve disc (25). The switching
pressure is taken via an impulse line from the outlet
pressure area of the regulating section and is
temporarily delayed by the throttle effect of the
control orifice (11), so that even with a sudden
reduction of capacity and momentary pressure
increase resulting therefrom, no closure of the safety
shut off valve will be effected.
This alternating process repeats itself until a balance

prevails between the force of the spring and the
force of the gas pressure on the diaphragm (6),
depending on the throughput.
The measuring mechanism is separated from the

inlet pressure space by an O ring seal.
When the pressure rises above the value set with the
spring (12) the diaphragm (13) overcomes the
resistance of the operating stem (29). The blocking
spring (27) presses the valve disc (25) against the
valve seat thus closing the gas supply.
Function of the SBV safety relief valve

The safety relief valve (17) is sized so that if the
regulator fails, then the flow capacity of the orifice
(24) can be vented without any inadmissible rise in
outlet pressure. The venting pressure is approx. 30
mbar above the outlet pressure, 10%. The excess
pressure is released to the vent connection (8) via
the SBV and thence safely to open atmosphere.
Note:
06/1 to 09/1 pressure regulators are supplied as
standard with orange springs (30 to 70 mbar). Types
1 to 5 are fitted black springs (70 to 140 mbar).
The actual outlet pressure has to be determined for
each individual installation. This outlet pressure
should be quoted when ordering, as well as the
spring required. The pressure regulator will then be
supplied with the correct spring and label.
Scope of delivery:
1 Pressure regulating unit, comprising:
pressure regulator, SAV safety shut off valve and
SBV safety relief valve
1 Inlet pressure gauge with push button valve
1 Outlet pressure gauge with push button valve
Connection pieces, screws, nuts, gaskets, zustzlich
and additionally with type 5/1:
Stabilising section with connections and control line
for pressure regulator and SAV
The unit is tested for soundness.
Installation
In order to avoid damage and operational faults,
care must be taken that the connection line and
the regulator are free from contamination.
Jointing rings must be in place.
The pressure regulator is installed in such a way
that the directional arrow on the casing points in
the direction of the gas flow. Due to the spring
load, the installation of the pressure regulator is
independent of its position. Due to the flange
connection (21) between valve body and the
casing of the diaphragm on the one hand and the
valve body and the casing of the SAV on the other
hand, various installation possibilities are
available. In standard execution, regulator, SAV
and gas flow are horizontal. The assembly may
however be installed in any position, but care
must be taken that the outlet pressure is
re-adjusted accordingly.
A line leading into safe open atmosphere is
connected to the breather port (7) .
(For installation instructions see page 14).
Once the pressure regulating assembly has been
installed in the burners gas valve train, a
soundness test must be carried out in accordance
with the burner operating instructions.
Prior to commissioning, the pressure regulating
assembly must be tested for correct function,
including the closing of the SAV.
All local legislation and directives must be
observed.
Commissioning
Function test of the burner with ball valve closed
(see the burners installation and operating
instructions).
Setting pressure to be set according to the
burners installation and operating instructions.
The ball valve can be opened slowly.
It is usually necessary to re-adjust the outlet
pressure. To do this the sealing cap (5) must be
removed. By turning the adjusting screw (4), the
pressure can be set to the required value.
Pressure increases when turning clockwise.
Adjustments should only be made under gas flow
conditions. This can be done during operation, as
all gas carrying areas of the regulator are sealed.
Should a fault on the pressure regulator result in a
closure of the SAV (28), the valve can be reset
manually once the cause of the fault has been
eliminated. In order to open the SAV valve disc
(25), first the cover cap (15) is removed and then
the valve adjusting rod (14) is set to the point
where the operating stem (29) will re-engage. It
should be noted that a small quantity of gas is
discharged via the valve adjusting rod after the
cover cap (15) has been removed. It is necessary
for the plant working pressure to be below the set
response limit of the valve.
Afterwards the cover cap (15) with the sealing
gasket has to be replaced. The SAV (28) is ready
for operation. Check the cover cap (15) for leaks
(by using Nekal or soap solution).
Types 06/1 to 09/1 and 1/1 to 4/1
Atmosphere
Inlet pressure
Outlet pressure
Adjustment and operational check of the SAV

Once burner settings have been completed, a
controlled shut down is carried out.
SAV responds:
Increase shut off pressure by clockwise rotation of
the adjusting screw SAV (12) until there is no
further response on controlled shut down.
SAV does not respond:

Reduce shut off pressure by anti-clockwise
rotation of the adjusting screw, until SAV
responds on controlled shut down.
After determining the shut off pressure, turn the
setting screw 1/2 to 1 turn clockwise.
Check by means of further controlled shut downs
whether the SAV remains in the open position.
SAV cannot be reset

The blow off pressure of the SBV is always
approx. 30 mbar above the outlet pressure. If the
shut off pressure of the SAV is less than this
figure, reset is not possible.
SAV does not engage

Decrease pressure on the outlet side.
Type 5/1
Atmosphere
Inlet pressure
Outlet pressure
Visual test
A visual test is carried out during annual
maintenance, when the condition and operation of
the units are checked for deviations in the desired
conditions (gas throughput, gas pressure, set
points).
Sequence test
After the visual test, the setting and operation of the
pressure regulator, SAV and SBV are checked.
Please pay attention to the notes on page 15.
Maintenance
The pressure regulators require practically no
maintenance. Damage to the orifice (24), due to
contaminants in the gas is however possible.
Therefore a gas filter should be fitted upstream of the
pressure regulator.
Selection chart for outlet pressure pa:

200 mbar, 140 mbar, 100 mbar, 50 mbar
6/
1
Ty
pe
07
/1
4.0
Ty
pe
0
Example 2
8/
1
3.0
Ty
pe
0
3.5
2.5
2.0
Inlet pressure p [bar] before the regulator
Ty
pe
0
9/
1
1.5
1.0
0.9
0.8
0.7
0.6
0.5
Example 1
0.4
0.35
0.3
3
10
15
20
25
30
35
40
50
60
70
80 90 100
Q1req.
Flow rate Vn [m3/h] Natural Gas H, Hu,n = 10.35 kWh/m3, d = 0.606

Natural Gas L, Hu,n = 8.83 kWh/m3, d = 0.641
The type of regulator required can be selected using

the chart. The followingmust be known:
Gas type (calorific value, density)
Burner rating
Inlet pressure [bar]
Required outlet pressure pa.
Selection example 1
Gas type:
Natural Gas
Hu,n = 10.35 kWh/m3n , d = 0.606
Gas throughput:
90 m3n /h
Inlet pressure pe: 480 mbar
Outlet pressure pa: 100 mbar (valve train selection)
The type is determined by referring to the

intersection point of the flow rate and inlet pressure,
and selecting the regulator shown to the right.
1. Pressure loss p from DN 50 filter and ball valve

(see pressure loss chart, page 5) approx.. 1 mbar.
2. Selection chart gives type 3/1.
If a gas filter and ball valve are installed upstream, the

pressure loss of these components must be
deducted form the inlet pressure (see example).
Selection example 2
Gas type:
LPG, Propane
Hu = 25.89 kWh/m3n , d = 1.555
Burner rating:
4,556 kW
Gas throput VGas: 176 m3n /h
Gas throput, rel.
to Natural Gas:
275 m3n /h (see page 9)
Inlet pressure pe: 2.9 bar
1. Pressure loss p from DN 50 filter and ball valve
approx. 1 mbar.
2. Selection chart gives 5/1 (permitted operating
pressure of regulator type 3/1 is exceeded).
3. Check: partial load turndown 1,500 kW
Q2max = 520 m3n /h (Natural Gas) = 520/1,557 =
333 m3n /h; Propane Qmin = 1,500/25.89 =
58 m3n /h G turndown1:5.7 < 1:20.
The selection is therefore OK.
DN 80
outlet
DN 100
outlet
DN 150
outlet
6/
1a
Typ
e6
/1
3.0
Ty
pe
2.5
80
/1
5
50
/1
00
1.5
Ty
pe
8/
1
Ty
pe
7/
1
Ty
pe
25
/5
0
6/
1a
0/
80
2.0
1.0
0.9
pe
Ty
1a
6/
1
7/
e
p
Ty
00
/1
5
1
0.8
0.7
Ty
pe
9
8/
1
Ty
pe
0
/5
50
Ty
pe
7/
1
80
/1
00
50
/8
0
50
/5
0
Ty
pe
6/
1
Ty
pe
5/
1
Ty
pe
4/
1
3.5
0/
10
0
50
/8
0
25
/8
0
Typ
e5
/1
Typ
e3
/1
Typ
e1
/1
Typ
e2
/1
Typ
e5
/1
4.0
0.6
0.5
0
/5
50
e
Typ
8/1
/80
80
9
pe
y
T
0
10
0/
0
1
0.4
0.35
0.3
150
200
250
300 350 400
Q2req.
500
600 700 800 9001000
Q2max
The stabilising section at the outlet must be enlarged

in accordance with the gas flow rate, so that the
permissible velocity is not exceeded.
Note:
The flow rate curves comply to regulator standard
RG10. The maximum regulation deviation is 10%
of the desired outlet value. At the minimum
throughput qmin, the outlet pressure pa rises by 10%,
at the maximum throughput qmax, the outlet pressure
pa drops by 10%.
The gas pressure regulators are direct operating
regulators and have a turndown ratio of 20:1, which
means that the smallest adjustable flow quantity is
5% of the maximum flow rate. The max. flow rate can
be read off the flow rate curve for the appropriate
inlet pressure (see example 2).
1250 1500 1750 2000
2500 3000 3500 4000
5000
Conversion of LPG, Towns Gas etc. to equivalent Natural Gas throughputs:

VNat Gas = VGas x f
Examples:
Gas type
Propane
Butane
Towns Gas 1
Towns Gas 2
Towns Gas 3
Towns Gas 4
Application:
VGas = QBr /Hu,Gas
f =
dGas /dNat Gas =
dGas /0.641
Calorific value
Hu kWh/m3n
Density
kg/m3
Relative
density d
Correction
factor f
25.89
34.39
4.89
4.30
6.40
4.20
2.011
2.708
0.513
0.624
1.060
0.801
1.555
2.094
0.397
0.483
0.820
0.620
1.557
1.807
0.787
0.868
1.131
0.967
Burner rating
Value on Natural Gas axis
QBr
= 1500 kW, propane
VPropane = 1500 / 25.89 = 57.9 m3n /h
VNat Gas = 57.9 x 1.557 = 90.1 m3n /h
700 m3/h _________ DN 50
from1750 to 2700 m3/h ________ DN 100
from 700 to 1750 m3/h _________ DN 80
from 2700 m3/h _______________ DN 150
up to

Types 5/1 to 9
Technical Data:
Weishaupt
type
Connection
DN
Inlet
Outlet
Approx.
weight
kg
Order No.
Gas pressure regulator

Type
DN
Orifice
mm
max. inlet
pressure
bar
Outlet
pressure
mbar
Spring
colour
Product
ID number
5/1-25/50
5/1-25/80
25
25
50
80
46
58
151 336 2637/0

151 336 2653/0
RR 16-25-31-8N-033
RR 16-25-31-8N-033
25
25
31
31
4.0
4.0
100 210
100 210
green/white CE-0085 AQ 1103

6/1-50/50
6/1-50/80
50
50
50
80
44
57
151 336 2638/0

151 336 2639/0
RR 16-50-31-8N-033
RR 16-50-31-8N-033
50
50
31
31
4.0
4.0
100 210
100 210

6/1a-50/50
6/1a-50/80
6/1a-50/100
50
50
50
50
80
100
44
57
62
151 336 2663/0

151 336 2664/0
151 336 2665/0
RR 16-50-42-8N-033
RR 16-50-42-8N-033
RR 16-50-42-8N-033
50
50
50
42
42
42
4.0
4.0
4.0
100 210
100 210
100 210

7/1-50/50
7/1-50/80
7/1-50/100
50
50
50
50
80
100
54
68
73
151 336 2640/0

151 336 2641/0
151 336 2642/0
RR 16-50-54-12N-033
RR 16-50-54-12N-033
RR 16-50-54-12N-033
50
50
50
54
54
54
4.0
4.0
4.0
100 210
100 210
100 210
black
black
black
CE-0085 AQ 1103
CE-0085 AQ 1103
CE-0085 AQ 1103
8/1-80/80
8/1-80/100
8/1-80/150
80
80
80
80
100
100
86
100
120
151 336 2643/0

151 336 2644/0
151 336 2645/0
RR 16-80-82-12N-033
RR 16-80-82-12N-033
RR 16-80-82-12N-033
80
80
80
82
82
82
4.0
4.0
4.0
100 210
100 210
100 210
black
black
black
CE-0085 AQ 1103
CE-0085 AQ 1103
CE-0085 AQ 1103
100
100
100
150
122
149
151 336 2620/0

151 336 2627/0
12-4-12
12-4-12
100
100
107
107
2.0
2.0
100 210
100 210
silver
silver
CE-0085 AQ 1095
CE-0085 AQ 1095
9-100/100
9-100/150
The RR 16... regulator has an integral SAV with safety diaphragm, green spring, setting range 140 - 400 mbar (unit supplied set to 350 mbar)
Scope of delivery:
1 Outlet pressure gauge with push button valve
1 Bypass line with ball valve
1 Impulse line (pressure regulator)
1 Impulse line (SAV)

1 Stabilising piece with connections
1 Key for resetting SAV, with screw and gaskets
Unit supplied fully assembled and pressure tested.
Legend:
2 Gas pressure regulator
3 Setting screw (pressure regulator)
4 Cover
5 Spring (pressure regulator)
6 Diaphragm (pressure regulator)
7 Breather connection, 1
8 Impulse line connection (pressure regulator)
9 Setting screw (SBV)
10 Spring (SBV)
12 Vent line connection , 3/4
13 Diaphragm
14 Outlet pressure gauge with push button
15 Stabilising line
17 Impulse line (pressure regulator)
18 Intermediate piece
19 Orifice (pressure regulator)
20 Valve body
21 Base plate
22 Valve disc
23 Valve stem
24 SAV seat
26 Diaphragm (SAV)
27 Spring (SAV)
28 Setting screw (SAV)
30 Latch lever
31 SAV valve
32 Reset shaft
Atmosphere
Inlet pressure
Outlet pressure
10
Types 9-100/100 and 9-100/150 only
Types 5 to 9
SAV
type
DN
Spring
colour
Setting
range
mbar
Pemax.
bar
Product
ID Number
SH-I
100
green
140 310
CE-0085 AQ 1096
SBV
type
275 D
DN
Spring
colour
Setting
range
mbar
Product
ID Number
black
150 500
CE-0085 AQ 1102
/4
Outlet pressure springs and labels

Outlet
pressure
mbar
Colour
Order No.
Label
Order No.
For use with type

5/1-25/50
6/1-50/50
5/1-25/80
6/1-50/80
15 35
15 35
15 35
orange/grey
yellow/black
green
490 190
490 191
490 085
2010000811/7
2010000811/7
2010000811/7
30 70
30 70
30 70
yellow/black
red/blue
orange
490 191
490 192
490 086
2010000812/7
2010000812/7
2010000812/7
70 140
70 140
70 140
red/blue
blue/green
black
490 192
490 193
490 087
2010000814/7
2010000814/7
2010000814/7
100 210
100 210
100 210
green/white
black
silver
490 194
490 195
490 088
2010000815/7
2010000815/7
2010000815/7
Note:
The pressure regulators are fitted as standard with
springs for the highest outlet pressure (see table
technical data). The actual outlet pressure must be
determined for the individual installation. This outlet
pressure and the required spring must be shown on
the order. The pressure regulators will then be
supplied with the relevant spring and adhesive plate.
7/1-50/50
7/1-50/80
7/1-50/100
8/1-80/80
8/1-80/100
8/1-80/150
9-100/100
9-100/150
Function of the pressure regulator

The pressure regulators diaphragm (6) transfers
movement via the valve stem (23) to the valve disc
(22). The outlet pressure is transferred via the
impulse line (17) into the space below the
diaphragms (6). This pressure is set with the setting
screw (3) and can be varied by adjsuted the spring
(5) loading. At zero gas flow the pressure regulator
(2) is closed. The valve disc (22) tightly closes the
orifice (19). Without gas pressure the pressure
regulator (2) is open. The spring tension presses the
diaphragm (6) and the valve stem (23) downward.
The valve disc (22) is thus lifted off the orifice (19).
When gas flows through the orifice (19), pressure
can build up via the impulse line (17) below the
diaphragm (6). If the gas pressure exceeds the set
spring tension, the valve stem (23) and valve disc
(22) are lifted and the orifice (19) is constricted. The
gas flow is thus reduced and the pressure rise
terminated. If the gas pressure behind the orifice (19)
drops due to gas reduction, the valve cross section
is again enlarged by the increased spring tension.
Function of the SAV safety shut off valve
During normal operation the SAV is open. It
automatically shuts off the gas flow if the pressure
rises above the set amount. After responding it
remains shut and can only be re-opened manually.
The shut off valve disc, coated with vulcanised
synthetic rubber, is spring loaded and is retained by
the latch lever (30) in the open position. Once the
trip pressure downstream of the valve has been
reached, the shut off valve is tripped and shut by the
spring tension.
As the gas flow presses the valve tightly onto the

valve seat, a tight seal is achieved. The SAV is reset
by the reset shaft (32).The shut off point of the SAV
is set via the setting screw (27). The SAV must not
be set above the maximum pe of the downstream
solenoid valves
Direction
of flow
Release principle
Function of the SBV safety relief valve

During normal operation the SBV is closed. The SBV
(11) is adjusted in such a manner that that this valve
will be the first to respond to an excess outlet
pressure. Only then will the SAV (29) become
operative. The gas is vented into safe open
atmosphere via the vent line (12). With a pressure
rise the diaphragm (13) is raised by the valve disc
and gas can thus flow through the valve. When the
diaphragm drops again following a reduction in
pressure, the valve is closed.
The appropriate venting pressure level is set via the
setting screw (9).
11
Installation
In order to avoid damage and operational faults,
care must be taken that the connection line and
the regulator are free from contamination.
Install horizontally, with the spring housing of the

gas pressure regulator vertically upwards.
The assembly must be installed in such a manner

that the directional arrows on the regulator and on
the SAV point in the direction of the gas flow.
When installing, particular care must be taken to

ensure the impulse lines (16 & 17) are not
damaged.
The vent line connection (12) should be connected

to the 3/4 breather port and led into a safe, open
atmosphere.
Once the pressure regulating assembly has been

installed in the burners gas valve train, a
soundness test must be carried out in accordance
with the burner operating instructions.
Prior to commissioning, the pressure regulating

assembly must be tested for correct function,
including the closing of the SAV.
All local legislation and directives must be

observed.
Commissioning
Slowly open the shut off assembly on the inlet
pressure side.
The outlet pressure of the pressure regulator (8),

the shut off pressure of the SAV (2) and the shut
off pressure of the SBV (17) are factory preset as
follows:
Pressure regulator ___________ approx. 140 mbar
SAV _______________________ approx. 350 mbar
SBV_______________________ approx. 300 mbar
If a different outlet pressure is required, this can be
achieved by adjusting the setting screw (3). For
instructions on pressure adjustment see page 15.
Should an operational fault on the pressure

regulator effect a closure of the SAV (2) it can be
reopened manually at the reset shaft (32), after
previously opening the ball valve in the bypass line
(equalisation of pressure).
Visual test
A visual test is carried out during annual
maintenance, when the condition and operation of
the units are checked for deviations in the desired
conditions (gas throughput, gas pressure, set
points).
Sequence test
After the visual test, the setting and operation of the
pressure regulator, SAV and SBV are checked.
Please pay attention to the notes on page 15.
Maintenance
The pressure regulators require practically no
maintenance. A gas filter must be fitted upstream of
the pressure regulator.
12
Faults
Vibration: The regulator is frequently held responsible
for pulsations, whereas in reality pulsations originate
mainly in the pipe line. A close check should therefore
be made first, as to whether the pipe line is well
supported and does not have any points causing
vibrations (half opened valves, pipework with many
changes in direction etc.).
Pulsation in the regulator can only be caused by a
distorted diaphragm or valve rods, which happens
very rarely.
Fluctuations (surges): The regulator has a large orifice
and consequently a very large throughput in
comparison to its connection size. At very low
throughputs the valve disc barely lifts from the orifice.
When this happens the regulator may become
unstable. To overcome this proceed as follows:
If the regulator surges at normal throughput the fault
can be rectified by throttling the impulse line.
Generally, a reduction in the cross section of the
impulse line effects an attenuation and consequently a
slower response period for the pressure regulator.
Surging of the regulator can often be eliminated by
reducing the breather cross section (see rubber
washer, page 13).
Where operating conditions permit, a different spring
may also be used.
No zero cut off: The cause may be a damaged valve
seat, or a non-tight orificie.
Note:
All SAV impulse connections are fitted as standard
with a 1.6 mm orifice. All RR16 regulators are
fitted as standard with a 3 mm orifice. This should
be checked if the equipment does not function
correctliy.
Connections / Accessories
Weldable flange Flange table: DIN 2633 PN 16

DN
Approx. kg
Order No.
20/ 26.9
25/ 33.7
40/ 48.3
38
38
42
0,9
1,1
1,8
452 940
452 941
452 942
50/ 60.3
65/ 76.1
80/ 88.9
45
45
50
2,5
3,0
3,7
452 936
452 910
452 911
100/114.3
125/139.7
150/168.3
52
55
55
4,6
6,3
7,7
452 913
452 914
452 918
Flanged eccentric reducer; aluminium

(Max. operating pressure 3 bar, flange table: DIN 2633 PN 16.
not for installation upstream of the high pressure regulator).
DN1
DN2
25
25
25
25
40
50
65
80
144
159
172
177
7.5
12.5
20.0
27.5
Approx. kg*
2.6
2.7
3.3
3.7
Order No.
151 329 2630/2
151 329 2631/2
151 329 2632/2
151 329 2683/2
40
40
40
40
50
65
80
100
163
177
181
195
5.0
12.5
20.0
31.0
3.7
4.1
4.4
6.0
151 329 2634/2

151 329 2635/2
151 329 2684/2
151 329 2637/2
50
50
50
65
80
100
180
185
197
7.5
15.0
26.0
4.4
5.1
6.3
151 329 2638/2

151 329 2685/2
151 329 2640/2
65
65
65
80
100
125
185
197
227
7.5
18.5
31.0
5.1
6.6
7.7
151 329 2686/2

151 329 2642/2
151 329 2643/2
80
80
100
125
207
232
11.0
23.5
7.0
8.2
151 329 2687/2

151 329 2688/2
100
100
125
125
150
150
234
247
250
12.5
26.5
14.0
9.4
12.0
12.8
151 329 2646/2

151 329 2647/2
151 329 2648/2
Includes nuts, bolts and gaskets for two break points.

Flanged concentric reducer; steel, grey cast iron or ductile cast iron
(Max. operating pressure 16 bar, flange table DIN 2633 PN 16).
DN1
DN2
Material
25
25
25
25
40
50
65
80
150
165
173
182
Steel
Steel
Steel
Steel
4.5
5.3
6.0
7.0
151 327 2671/2

151 327 2680/2
151 330 2620/2
151 330 2621/2
40
50
50
50
50
65
80
100
200
200
200
200
Grey cast iron

Grey cast iron
Ductile cast iron
Ductile cast iron
7.0
9.0
7.2
8.1
151 330 2625/2

151 327 2682/2
151 329 2689/2
151 327 2644/2
65
80
80
80
80
100
125
150
200
200
200
200
Ductile cast iron

Ductile cast iron
Ductile cast iron
Ductile cast iron
8.2
9.3
10.5
12.0
151 330 2608/2

151 329 2690/2
151 329 2691/2
151 330 2622/2
100
100
125
125
150
150
200
200
200
Ductile cast iron

Ductile cast iron
Ductile cast iron
11.4
12.8
14.1
151 327 2689/2

151 328 2626/2
151 330 2623/2
Approx. kg*
Order No.
Includes nuts, bolts and gaskets for two break points.

Rubber washer
Dimensions
Order No.
44 mm, 2 mm thick
151 336 2616/7
See page 10 for notes and installation.
* the weights given include nuts, bolts and gaskets.

Dimensions are approximate. We reserve the right t make changes in the light of future developments.
13
Installation examples and notes
1
2
3
4
5
6
7
8
9
10
Ball valve
Gas filter
SAV safety shut off valve
Pressure regulator
Compensator
Reducing flange
Pressure gauge with push button valve
SBV vent line
Pressure regulator breather line
Installation instructions
In many cases the pressure regulators inlet and
outlet sizes are smaller than those of the gas
valve trains other components, particularly with
high gas pressures. A range of flanged reducers
in all the necessary sizes is available to enable
installation to be carried out quickly and correctly
(see page 13).
The distance between the solenoid valves and

the pressure regulator can be short, or several
meters long. With large distances the gas flow
can stabilise and a buffer volume is obtained.
There must be an ambient temperature of - 15C

to + 60C for the pressure regulators and the
safety assemblies. If necessary, the regulators
should be shielded from heat radiation or
excessively low temperatures. Protection is also
necessary against damp, dust and dirt.
Example: installation with pressure regulator types 08/1 to 09/1 and 1/1 to 4/1
The breather line (10) is the line between the

space above the diaphragm of the pressure
regulator or safety shut off valve and free
atmosphere. Correct operation can only be
guaranteed if the air column above the
diaphragm can move quickly without undue
resistance. The line diameters below must be
provided for the various lengths of line as shown.
mm
length m
15
20
25
3
5
>5
For longer lengths up to 30 m, 25 mm is

sufficient.
Due to the SAV shut off cap ,which is fitted with a

diaphragm, it is not necessary to fit a breather
line from the SAV diaphragm housing to
atmosphere.
Multiple breather lines from the gas pressure

regulator can be manifolded together or
separately over the roof. The common line must
be laid with a larger diameter. It should be noted
that no mutual interference is caused by this.
The vent line (9) is the line between the safety

relief valve and free atmosphere. This line must
be installed separately
Example: installation with pressure regulator types 5/1 to 8/1
Connection for types 5/1 to 9 ____________ 3/4
There is a common breather and vent line (9/10)

on pressure regulator types 08/1 and 09/1 and
types 1/1 to 5/1. This line must be installed
separately. For the nominal diameter, the same
instructions as for the breather line apply.
Connection for:
Types 08/1 and 09/1 ___________________ 3/4
Types 1/1 to 5/1 ________________________ 1
14
The termination of the lines must be an adequate

distance from sources of ignition (at least 3
metres) and and installed so that any outflowing
gas cannot enter buildings. The line must also be
protected against the entry of rainwater and
against blockages.
Attention must be paid to installation expansion

and movement. Compensators can be used for
this.
The gaskets supplied should be inserted

between the flanges.
The complete assembly must be tested for

soundness before commissioning. The outlet
side is tested according to the instructions given
in the burner installation and operating manual.
For valve proving of the inlet side see page 15.
Prior to commissioning, check for correct

function, including the closed position test of the
safety shut off valve. The installation must be
purged carefully and the pressure increased by
slowly filling with gas.
Notes on adjustment
Fig. 1
Fig. 2
Fig. 3
Adjusting the outlet pressure (Fig. 1)

When reading the pressure gauge, the push
button valve must be depressed.
Adjusting the SBV (Fig. 2)

The SBV is factory preset to 300 mbar
The SAV is factory preset to 350 mbar
This setting does not normally require an
This setting does not normally require an
The outlet pressure of the regulator can be
decreased by turning the setting screw (item 3,

page 10) anticlockwise, and increased by turning
the screw clockwise.
adjustment
The setting pressure of the SBV can be

page 10) anticlockwise and increased by turning
The relief pressure must be lower than the max.
permitted inlet pressure of the solenoid valve.
Adjusting the SAV (Fig. 3)
adjustment
The setting pressure of the SAV can be

page 10) anticlockwise and increased by turning
The setting pressure may only be as high as the
max. permitted setting pressure of the solenoid

valves.
The SAV cannot be reset
This occurs if the SBVs vent pressure is set higher
than the tripping pressure of the SAV.
Fig. 4
Fig. 5
Fig. 6
Reseting the SAV

Equalise the pressure by opening the bypass
valve (Fig. 4).
Unscrew sealing cap and pull back valve rod until
Turn reset shaft anticlockwise until the valve disc
it engages (Fig. 5, only possible if the outlet

pressure is less than the SAV release pressure).
arm in the release arm engages (Fig. 6).

Screw on sealing cap.
Manual bypass valve must be closed.
Soundness test:
Once installed and prior to commissioning, the
complete regulator assembly has to be tested for
soundness, in accordance with the instructions given
in the burners installation and operating manual (the
connection of a filter is possible during the 1st test
phase of the soundness test).
SAV soundness test:
Checking the regulators zero shutdown:
Activate the SAV by increasing the pressure
Open the ball valve and wait until the outlet
downstream of the regulator.

Release pressure in the regulator section by
opening the test point downstream of the

regulator. (ball valve closed).
Connect a pressure gauge to the test point and
check if the pressure increases when the ball

valve is opened.
pressure of the regulator is constant.

Note: SBV must be closed!
Close ball valve
Check if the pressure difference between the
regulators inlet and outlet remains constant.
15
Dimensions
Max Weishaupt GmbH

D-88475 Schwendi
Tel (0 73 53) 8 30, Fax (0 73 53) 8 33 58
www.weishaupt.de
Print No. 83001202, October 2006
Printed in Germany. All rights reserved.
Neachells Lane, Willenhall, WV13 3RG
Tel (01902) 609841, Fax (01902) 633343
www.weishaupt.co.uk
Fig. 1 Types 06/1 to 09/1 and 1/1 to 4/1
Types
d1/d2
06/1 to 09/1
1/1 to 4/1
25
50
d3
d4
h1
h1*
h2
h3
190
350
/4
1
155
250
345
445
100
100
380
490
l4
l5
l6
160
260
100
150
Types
l1
l2
l3
06/1 to 09/1
1/1 to 4/1
160
200
250
290
100
110
60
60
* Dimension for disassembling spring
Flange
DIN 2633
Fig. 2 Type 5/1 (compact)
Dimensions in mm are approximate

(Counterflange not included in delivery, for exact scope of delivery see page 6)
Type
d2
d1
5/1
50
50
l1
l2
h1
h2
h2*
200
750
490
250
445
Flange
DIN 2633
All other dimensions as per types 1/1 to 4/1.
Fig. 3 Types 5/1 to 8/1
d31)
d4
d6
h1
h1*
h2
5/1-25/50
5/1-25/80
25
25
50
80
310
310
1
1
190
190
470
470
660
660
195
195
6/1-50/50
6/1-50/80
50
50
50
80
310
310
1
1
190
190
485
485
680
680
195
195
6/1a-50/50
6/1a-50/80
6/1a-50/100
50
50
50
50
80
100
310
310
310
1
1
1
190
190
190
485
485
485
680
680
680
195
195
195
7/1-50/50
7/1-50/80
7/1-50/100
50
50
50
50
80
100
405
405
405
1
1
1
190
190
190
485
485
485
680
680
680
195
195
195
8/1-80/80
8/1-80/100
8/1-80/150
80
80
80
80
100
150
405
405
405
1
1
1
190
190
190
545
545
545
735
735
735
240
240
240
l5
Types
3
G /4 reverse
Pressure regulator
RR 16
Flange
DIN 2633
1) Diaphragm and largest width
Fig. 4 Type 9
Flange DIN 2633
d1
d2
Types
h3
h4
h5
l1
l2
l3
l4
5/1-25/50
5/1-25/80
430
430
350
360
280
280
133
133
180
180
847
1016
250
250
95
95
6/1-50/50
6/1-50/80
430
430
350
350
295
295
179
179
250
250
752
1104
250
250
95
95
6/1a-50/50 430
6/1a-50/80 430
6/1a-50/100 460
350
350
370
295
295
295
179
179
179
250
250
250
752
1104
1204
250
250
250
95
95
95
7/1-50/50
7/1-50/80
7/1-50/100
430
450
460
350
360
370
295
295
295
179
179
179
250
250
250
752
1104
1204
250
250
250
95
95
95
8/1-80/80
450
8/1-80/100 460
8/1-80/150 480
360
370
400
355
355
355
210
210
210
300
300
300
952
1254
1254
250
250
250
95
95
95
Types
d1
d2
d31)
d4
d5
9-100/100
9-100/150
100
100
100
150
360
360
1
1
Types
h2
h3
h4
l1
9-100/100
9-100/150
365
365
455
480
375
400
350
350
1)
*
Diaphragm and largest width

Dimension for disassembling spring
d6
h1
h1*
190
190
425
425
620
620
l2
l3
l4
350
350
1455
1655
250
250
/2
1
/2
VLTAutomationDrive FC 300 Produkthandbuch
Inhaltsverzeichnis
Inhaltsverzeichnis
1. Lesen des Produkthandbuchs
Zulassungen
Symbole
Abkrzungen
2. Sicherheitshinweise und Allgemeine Warnung
Hochspannung
Vermeiden des unerwarteten Anlaufs
Sicherer Stopp des FC 300
Installation Sicherer Stopp (nur FC 302 und FC 301 mit A1-Gehuse)
11
IT-Netz
11
3. Installieren
13
Mechanische Installation
16
Elektrische Installation
21
Netzanschluss und Erdung
22
Motoranschluss
25
Sicherungen
28
Elektrische Installation, Steueranschlsse
32
Anschlussbeispiele
33
Start/Stopp
33
Puls Start/Stopp
33
Drehzahl auf/ab
34
Potentiometer-Sollwert
34
Elektrische Installation, Steuerkabel
35
Schalter S201, S202 und S801
36
Zustzliche Verbindungen
40
Mechanische Bremssteuerung
40
Thermischer Motorschutz
40
4. Programmieren
41
Die grafische und numerische Bedieneinheit
41
Programmieren an der grafischen LCP-Bedieneinheit
41
Programmieren an der numerischen LCP-Bedieneinheit
42
Inbetriebnahme-Men
44
Parameterlisten
48
5. Allgemeine technische Daten
77
6. Fehlersuche und -behebung
83
Warnungen/Alarmmeldungen
MG.33.AA.03 - VLT ist eine eingetragene Marke von Danfoss.
83
Inhaltsverzeichnis
Index
91
1.1.1. Lesen des Produkthandbuchs

VLT AutomationDrive FC 300 dient zur Regelung der Drehzahl bzw. des Drehmoments an der Welle von elektrischen Motoren. Lesen Sie dieses Handbuch
sorgfltig durch. Eine unsachgeme Verwendung des Frequenzumrichters kann zu Fehlfunktionen des Umrichters und der angeschlossenen Gerte, zu
einer Verkrzung der Lebensdauer oder zu anderen Problemen fhren.
Mithilfe dieses Produkthandbuchs knnen Sie den VLT AutomationDrive FC 300 installieren und programmieren und gegebenenfalls Fehler beheben.
Der VLT AutomationDrive FC 300 ist in zwei Wellenleistungsniveaus lieferbar. Der VLT AutomationDrive FC 300 ist in zwei Wellenleistungsniveaus
lieferbar. Der FC 301 reicht von skalar (U/f) bis WC+ und kann nur mit Asynchronmotoren eingesetzt werden. Der FC 302 ist ein Hochleistungs-Frequenzumrichter fr Asynchron- und permanenterregte Motoren, der verschiedene Motorsteuerverfahren wie Skalar (U/f), VVC+ und Flux-Vektor
untersttzt.
Diese Bedienungsanweisungen gelten fr FC 301 und FC 302. Wenn Informationen fr beide Typen gelten, verwenden wir die Bezeichnung FC 300.
Andernfalls wird speziell auf FC 301 bzw. FC 302 verwiesen.
Kapitel 1, Lesen des Produkthandbuchs, gibt eine Einfhrung zum Handbuch und informiert ber Zulassungen, Symbole und Abkrzungen, die in
diesem Handbuch verwendet werden.
Kapitel 2, Sicherheitsanweisungen und allgemeine Warnungen, enthlt Anweisungen zur korrekten Handhabung des FC 300.
Kapitel 3, Installieren, fhrt Sie durch das mechanische und elektrische Installationsverfahren.
Kapitel 4, Programmieren, erklrt, wie Sie den FC 300 ber die LCP-Bedieneinheit bedienen und programmieren.
Kapitel 5, Allgemeine technische Daten , enthlt die technischen Daten zum FC 300.
Kapitel 6, Fehlersuche, hilft Ihnen, die Ursachen von Problemen, die beim Arbeiten mit dem FC 300 vorkommen knnen, ausfindig zu machen und zu
beheben.

Verfgbare Literatur fr FC 300
-
Die VLT AutomationDrive FC 300 Bedienungsanweisungen liefern die erforderlichen Informationen fr die Inbetriebnahme und den Betrieb
des Frequenzumrichters.
Das Projektierungshandbuch zum VLT AutomationDrive FC 300 enthlt alle technischen Informationen zum Frequenzumrichter sowie Informationen zur kundenspezifischen Anpassung und Anwendung.
Das Produkthandbuch zum VLT AutomationDrive FC 300 Profibus enthlt Informationen zum Steuern, berwachen und Programmieren des
Frequenzumrichters ber einen Profibus-Feldbus.
Das Produkthandbuch zu VLT AutomationDrive FC 300 DeviceNet enthlt Informationen zum Steuern, berwachen und Programmieren des
Frequenzumrichters ber die DeviceNet-Schnittstelle.
Das Produkthandbuch zu VLT AutomationDrive FC 300MCT 10 enthlt Informationen zur Installation und Verwendung der Software auf einem
PC.
Das Handbuch zu VLT AutomationDrive FC 300 IP21 / Typ 1 enthlt Informationen zur Installation der Option IP21/Typ 1.
Das Handbuch zu VLT AutomationDrive FC 300 24 V DC Backup enthlt Informationen zur Installation der Option fr die 24 V DC-Notstromversorgung.
Technische Literatur von Danfoss Drives ist ebenfalls verfgbar unter www.danfoss.com/drives.
1.1.2. Zulassungen
1.1.3. Symbole
In diesem Produkthandbuch verwendete Symbole.
ACHTUNG!
Kennzeichnet einen wichtigen Hinweis.
Kennzeichnet eine allgemeine Warnung.
Kennzeichnet eine Warnung vor Hochspannung.
Markiert in der Auswahl die Werkseinstellung.
1.1.4. Abkrzungen
Wechselstrom
American Wire Gauge = Amerikanisches Drahtma
Ampere
Automatische Motoranpassung
Stromgrenze
Grad Celsius
Gleichstrom
Abhngig von Frequenzumrichter
Elektromagnetische Vertrglichkeit
Elektronisch-thermisches Relais
Frequenzumrichter
Gramm
Grssenabhngig
Hertz
Kilohertz
LCP-Bedieneinheit
Meter
Induktivitt in Millihenry
Milliampere
Millisekunde
Minute
Motion Control Tool
Nanofarad
Newtonmeter
Nennmotorstrom
Motornennfrequenz
Nennmotorleistung
Nennmotorspannung
Parameter
Schutzkleinspannung
Platine (engl. Printed Circuit Board)
Wechselrichter-Ausgangsnennstrom
Umdrehungen pro Minute
Sekunde
Drehmomentgrenze
Volt
AC
AWG
A
AMA
ILIM
C
DC
D-TYPE
EMV
ETR
FC
g
SR
Hz
kHz
LCP
m
mH
mA
ms
min.
MCT
nF
Nm
IM,N
fM,N
PM,N
UM,N
Par.
PELV
PCB
IINV
UPM
s
TLIM
V
2
Gerte mit elektronischen Bauteilen drfen nicht im normalen Hausmll entsorgt werden.
Sie mssen separat mit Elektro- und Elektronikaltgerten gem rtlicher und geltender Gesetzgebung gesammelt werden.
Die Zwischenkreiskondensatoren bleiben auch nach Abschalten der Netzversorgung eine gewisse Zeit geladen. Zum Schutz vor elektrischem Schlag ist der Frequenzumrichter vor allen Wartungsarbeiten vom Netz zu trennen. Bei Verwendung eines PM-Motors
sicherstellen, dass dieser getrennt ist. Vor der Durchfhrung von Wartungsarbeiten mssen unbedingt die folgenden Wartezeiten
eingehalten werden:
380 - 500 V
525 - 690 V
0,25 - 7,5 kW
11 - 75 kW
90 - 200 kW
250 - 400 kW
37 - 250 kW
315 - 560 kW
4 Minuten
15 Minuten
20 Minuten
40 Minuten
20 Minuten
30 Minuten
FC 300
Betriebsanleitung
Softwareversion: 4.8x
Dieses Produkthandbuch gilt fr smtliche FC 300-Frequenzumrichter mit Softwareversion 4.8x.

Die Softwareversion kann ber Parameter 15-43 aufgerufen werden.
2.1.1. Hochspannung
Der Frequenzumrichter steht bei Netzanschluss unter lebensgefhrlicher Spannung. Unsachgeme Installation des Motors oder des
Frequenzumrichters knnen Schden am Gert sowie schwere Personenschden oder sogar tdliche Verletzungen verursachen. Halten
Sie daher unbedingt die Anweisungen in diesem Handbuch sowie die lokalen und nationalen Sicherheitsvorschriften ein.
Installation in groen Hhenlagen

380 - 500 V: Bei Hhen ber 3 km ber NN ziehen Sie bitte Danfoss Drives zu PELV (Schutzkleinspannung) zurate.
525 - 690 V: Bei Hhen ber 2 km ber NN ziehen Sie bitte Danfoss Drives zu PELV (Schutzkleinspannung) zurate.
Der Frequenzumrichter steht bei Netzanschluss unter lebensgefhrlicher Spannung. Unsachgeme Installation des Motors, Frequenzumrichters oder Feldbus kann Schden am Gert sowie schwere Personenschden oder sogar tdliche Verletzungen verursachen.
Befolgen Sie daher stets die Anweisungen in diesem Handbuch sowie die rtlichen und nationalen Vorschriften und Sicherheitsbestimmungen.
Sicherheitsvorschriften
1.
Bei Reparaturen muss die Stromversorgung des Frequenzumrichters abgeschaltet werden. Vergewissern Sie sich, dass die Netzversorgung
unterbrochen und die erforderliche Zeit verstrichen ist, bevor Sie die Motor- und Netzstecker entfernen.
2.
Die [OFF]-Taste auf dem Bedienfeld des Frequenzumrichters unterbricht nicht die Netzspannung und darf deshalb nicht als Sicherheitsschalter
benutzt werden .
3.
Es ist dafr Sorge zu tragen, dass gem den rtlichen und nationalen Vorschriften eine ordnungsgeme Schutzerdung des Gertes erfolgt,
der Benutzer gegen Versorgungsspannung geschtzt und der Motor gegen berlast abgesichert wird.
4.
Der Erdableitstrom bersteigt 3,5 mA.
5.
Ein berlastungsschutz des Motors ist in der Werkseinstellung nicht enthalten. Wenn diese Funktion erforderlich ist, stellen Sie Par. 1-90 auf
Datenwert ETR Alarm 1 [4] oder Datenwert ETR Warnung 1 [3] ein.
6.
Die Stecker fr die Motor- und Netzversorgung drfen nicht entfernt werden, wenn der Frequenzumrichter an die Netzspannung angeschlossen
ist. Vergewissern Sie sich, dass die Netzversorgung unterbrochen und die erforderliche Zeit verstrichen ist, bevor Sie die Motor- und Netzstecker
entfernen.
7.
Der VLT-Frequenzumrichter hat auer den Spannungseingngen L1, L2 und L3 noch weitere Spannungseingnge, wenn DC-Zwischenkreiskopplung bzw. externe 24 V DC-Versorgung installiert sind. Kontrollieren Sie, dass vor Beginn der Reparaturarbeiten alle Spannungseingnge
abgeschaltet sind und die erforderliche Zeit verstrichen ist.
2.1.2. Allgemeine Warnung

Warnung:
Das Berhren spannungsfhrender Teile auch nach der Trennung vom Netz ist lebensgefhrlich.
Achten Sie darauf, dass alle Spannungseingnge, wie z. B. die Zwischenkreiskopplung (Zusammenschalten von Gleichstrom-Zwischenkreisen) sowie der Motoranschluss (z. B. bei kinetischem Speicher), abgeklemmt wurden.
Verwendung des VLT AutomationDrive FC 300: mindestens 15 Minuten warten.
Eine krzere Wartezeit ist nur mglich, wenn dies auf dem Typenschild des jeweiligen Gerts entsprechend vermerkt ist.
Ableitstrom
Der Ableitstrom des FC 300 bersteigt 3,5 mA. Um einen guten mechanischen Anschluss des Erdungskabels an Erde (Klemme 95)
sicherzustellen, muss z. B. der Kabelquerschnitt mindestens 10 mm2 betragen, oder es mssen 2 getrennt verlegte Erdungskabel
verwendet werden.
Fehlerstrom-Schutzeinrichtungen
Dieses Gert kann einen Fehler-Gleichstrom im Schutzleiter verursachen. Als Fehlerstromschutzschalter (FI-Schutzschalter) darf netzseitig nur Typ B (allstromsensitiv) verwendet werden. Siehe auch die FI-Anwendungshinweise MN.90.GX.02.
Die Schutzerdung des FC 300 und die Verwendung von FI-Schutzschaltern mssen stets in bereinstimmung mit den nationalen und
lokalen Vorschriften erfolgen.
2.1.3. Bevor Sie Reparaturarbeiten ausfhren
1.
Trennen Sie den Frequenzumrichter vom Netz.
2.
Trennen Sie die DC-Zwischenkreisklemmen 88 und 89 von Lastteilungsanwendungen.
3.
Warten Sie, bis keine Spannung mehr an der Klemme anliegt. Die Wartezeiten sind auf dem Warnschild vermerkt.
4.
Entfernen Sie das Motorkabel.
2.1.4. Vermeiden des unerwarteten Anlaufs

Solange der FC 300 an die Netzversorgung angeschlossen ist, kann der Motor ber digitale Befehle, Busbefehle, Sollwerte oder ber die LCP-Bedieneinheit
gestartet bzw. gestoppt werden.
Trennen Sie den FC 300 vom Stromnetz, wenn ein ungewollter Start aus Grnden des Personenschutzes verhindert werden soll.
Um einen ungewollten Start zu vermeiden, bettigen Sie stets die [OFF]-Taste, bevor Sie Parameter ndern.
Ein elektronischer Fehler, eine vorbergehende berlast, ein Fehler in der Netzversorgung oder ein Verlust des Motoranschlusses kann bewirken,
dass ein gestoppter Motor anluft. Die Funktion des Sicheren Stopps beim FC 300 (d. h. FC 301 mit A1-Gehuse und FC 302) schtzt vor einem
unerwarteten Anlauf, wenn an Klemme 37 nur eine geringe Spannung anliegt oder die Klemme von der Stromversorgung getrennt ist.
2.1.5. Sicherer Stopp des FC 300

Der FC 302 und der FC 301 mit A1-Gehuse sind fr Installationen mit der Sicherheitsfunktion Sichere Abschaltung Motormoment (nach IEC 61800-5-2)
oder Stoppkategorie 0 (nach EN 60204-1) geeignet.
FC 301 mit A1-Gehuse: Wenn der Frequenzumrichter mit der Funktion Sicherer Stopp ausgestattet ist, muss Position 18 des Typencodes T oder U
lauten. Lautet Position 18 B oder X, ist sicherer Stopp ber Klemme 37 nicht vorgesehen!
Beispiel:
Typencode fr FC 301 A1 mit Sicherem Stopp: FC-301PK75T4Z20H4TGCXXXSXXXXA0BXCXXXXD0
Er ist fr die Anforderungen der Sicherheitskategorie 3 in EN 954-1 ausgelegt und als dafr geeignet zugelassen. Diese Funktion wird als Sicherer Stopp
bezeichnet. Vor der Integration und Benutzung der Funktion Sicherer Stopp des Frequenzumrichters in einer Anlage muss eine grndliche Risikoanalyse
der Anlage erfolgen, um zu ermitteln, ob die Funktion Sicherer Stopp und die Sicherheitskategorie des Frequenzumrichters angemessen und ausreichend
sind. Zur Installation und zum Gebrauch der Funktion Sicherer Stopp gem den Anforderungen von Sicherheitskategorie 3 in EN 954-1 mssen die
zugehrigen Informationen und Anweisungen des FC 300-Projektierungshandbuchs MG.33.BX.YY befolgt werden! Die Informationen und Anweisungen
des Produkthandbuchs reichen zum richtigen und sicheren Gebrauch der Funktion Sicherer Stopp nicht aus!
10
2.1.6. Installation Sicherer Stopp (nur FC 302 und FC 301 mit A1-Gehuse)
Die Installation der Stoppkategorie 0 (EN 60204) gem Sicherheitskategorie 3 (EN 954-1) ist folgendermaen auszufhren:
1.
Entfernen Sie die werksseitig angebrachte Kabelbrcke zwischen Klemme 37 und Klemme 12 (24 V DC). Es reicht nicht aus,
das Kabel nur durchzuschneiden oder zu unterbrechen. Es muss
vollstndig entfernt werden, um Fehlkontaktierung zu vermeiden. Siehe Kabelbrcke in Abbildung.
2.
Schlieen Sie Klemme 37 mit einem gegen Kurzschluss geschtzten Kabel (verstrkte Isolation) ber eine Sicherheitsvorrichtung gem EN 954-1 Kategorie 3 an die 24-V-DCVersorgung an. Sind die Sicherheitsvorrichtung und der
Frequenzumrichter im selben Schaltschrank untergebracht, darf
auch ein normales Kabel verwendet werden.
3.
Sofern der FC 302 nicht Schutzart IP54 oder hher hat, muss er
in ein IP54-Gehuse eingesetzt werden. Daher muss ein FC 301
A1 immer in ein IP54-Gehuse gesetzt werden.
Abbildung 2.1: Kabelbrcke (Jumper) zwischen Klemme 37 und Klemme 12 (24 V DC)
Die folgende Abbildung zeigt als Beispiel eine Anwendung mit Stoppkategorie 0 (EN 60204-1) gem Sicherheitskategorie 3 (EN 954-1). Klemme 37 wird
ber einen Sicherheitsbaustein (der auch Kategorie 3 nach EN 954-1 erfllen muss) geschaltet. Der zustzliche abgebildete Freilaufkontakt ist nicht
sicherheitsbezogen und erfllt nicht Kategorie 3 nach EN 954-1.
Abbildung 2.2: Abbildung der wesentlichen Aspekte einer Installation zum Erzielen der Stoppkategorie 0 (EN 60204-1) mit Sicherheitskategorie 3 (EN
954-1).
2.1.7. IT-Netz
Par. 14-50 EMV 1 kann benutzt werden, um in Frequenzumrichtern mit einem Spannungsbereich von 380 - 500 V die internen Funkenstrkondensatoren
vom EMV-Filter an Erde zu trennen. Wenn dies geschieht, wird die EMV-Leistung auf das Niveau A2 reduziert. Bei 525 - 690 V-Frequenzumrichtern hat
Par. 14-50 keine Funktion. Der EMV-Schalter kann nicht geffnet werden.
11
3. Installieren
12
3. Installieren
3. Installieren
3.1.1. Vorgehensweise bei der Installation
In diesem Kapitel wird die mechanische und elektrische Installation an den Leistungsklemmen und Steuerkartenklemmen beschrieben.
Die elektrische Installation von Optionen ist im entsprechenden Profihandbuch und Projektierungshandbuch beschrieben.
3.1.2. Erste Schritte

Fhren Sie die unten beschriebenen Schritt-fr-Schritt-Anweisungen aus, um den FC 300 schnell und EMV-gerecht zu installieren.
Lesen Sie die Sicherheitshinweise, bevor Sie das Gert

installieren.
Netzanschluss und Erdung
Motoranschluss und Verkabelung
Sicherungen und Trennschalter
Steuerklemmen - Kabel
Inbetriebnahme-Men
Lokale Bedieneinheit (LCP)
Automatische Motoranpassung, AMA
Programmierung
Abbildung 3.1: Die Grafik zeigt die grundlegende Installationskonfiguration, einschlielich Stromnetz, Motor, Start/Stopp-Taste und Potentiometer fr die Drehzahleinstellung.
13
3. Installieren
Die Gehusegre hngt vom Gehusetyp, der Leistung und der Netzspannung ab.
Gehusetyp
A1
A2
A3
A5
3
Gehuse
IP
20/21
Gehuse/Typ 1
Absicherung NEMA
Nenn0,25-1,5 kW (200-240 V)
Leistung
0,37-1,5 kW (380-480 V)
20/21
Chassis/Typ 1
0,25-3 kW (200-240 V)
0,37-4,0 kW (380-480/ 500V)
0,75-4 kW (525-600 V)
B2
20/21
55/66
Chassis/Typ 1
Typ 12/Typ 4X
3,7 kW (200-240 V)
0,25-3,7 kW (200-240 V)
5,5-7,5 kW (380-480/ 500 V) 0,37-7,5 kW (380-480/500 V)
5,5-7,5 kW (525-600 V )
0,75 -7,5 kW (525-600 V)
B3
B4
Gehuse
IP
21/55/66
Typ 1/Typ 12
Absicherung NEMA
Nenn5,5-7,5 kW (200-240 V)
Leistung
11-15 kW (380-480/ 500V)
11-15 kW (525-600 V)
Gehusetyp
C1
21/55/66
Typ 1/Typ 12
11 kW (200-250 V)
18,5-22 kW (380-480/ 500V)
18,5-22 kW (525-600 V)
C2
20
Chassis
5,5-7,5 kW (200-240 V)
11-15 kW (380-480/500 V)
11-15 kW (525-600 V)
C3
20
Chassis
11-15 kW (200-240 V)
18,5-30 kW (380-480/ 500 V)
18,5-30 kW (525-600 V)
C4
Gehuse
IP
21/55/66
Absicherung NEMA
Typ 1/Typ 12
Nenn15-22 kW (200-240 V)
Leistung
30-45 kW (380-480/ 500V)
30-45 kW (525-600 V)
21/55/66
Typ 1/Typ 12
30-37 kW (200-240 V)
55-75 kW (380-480/ 500V)
55-90 kW (525-600 V)
20
Chassis
18,5-22 kW (200-240 V)
37-45 kW (380-480/500 V)
37-45 kW (525-600 V)
20
Chassis
30-37 kW (200-240 V)
55-75 kW (380-480/ 500 V)
55-90 kW (525-600 V)
Gehusetyp
14
B1
3. Installieren
Montagezubehr: Der Frequenzumrichter wird mit folgendem Montagezubehr geliefert:
Gehusegren A1, A2 und A3, IP20/Chassis
Gehusegre A5, IP55/Typ 12
Gehusegre B1 und B2
IP21/IP55/Typ 1/Typ 12
Gehusegre B3, IP20/Chassis
Gehusegre B4, IP20/Chassis
Gehusegre C1 und C2, IP55/66/Typ 1/Typ

Gehusegre C3, IP20/Chassis
Gehusegre C4, IP20/Chassis
12
1 + 2 nur bei Gerten mit Bremschopper. Es gibt fr den FC 301 nur einen Relaisanschluss. Fr die DC-Zwischenkreiskopplung kann Steckanschluss
1 separat bestellt werden (Bestellnummer 130B1064).
Fr den FC 201 ohne sicheren Stopp enthlt das Montagezubehr einen achtpoligen Stecker.
15
3. Installieren
3.2. Mechanische Installation

3.2.1. Mechanische Installation
Alle IP20-Gehusegren sowie die IP21/IP55-Gehusegren mit Ausnahme von A1*, A2 und A3 eignen sich zur Installation nebeneinander.
Beim IP21-Gehuse (130B1122 bzw. 130B1123) muss zwischen den Frequenzumrichtern ein Abstand von mindestens 50 mm eingehalten werden.
Fr optimale Khlbedingungen muss ber und unter dem Frequenzumrichter freier Luftdurchlass gewhrleistet sein. Siehe nachstehende Tabelle.
Luftdurchlass fr verschiedene Gehuse

Gehuse:
A1*
A2
A3
A5
B1
B2
B3
B4
C1
C2
C3
C4
a
(mm):
100
100
100
100
100
100
200
200
200
225
200
225
b
(mm):
100
100
100
100
100
100
200
200
200
225
200
225
Tabelle 3.1: * Nur FC 301.

1.
Sehen Sie die Befestigung gem den Angaben zu den Montagelchern vor.
2.
Verwenden Sie geeignete Schrauben fr die Oberflche, auf der der Frequenzumrichter montiert wird. Achten Sie auf ebene Auflage des Khlkrpers, und ziehen Sie alle vier Schrauben gut an.
Tabelle 3.2: Bei der Montage von Gren A5, B1, B2, B3, B4, C1, C2, C3 und C4 auf einer nicht stabilen Wand muss der Frequenzumrichter wegen
unzureichender Khlluft ber dem Khlkrper mit einer Rckwand A versehen werden.
16
3. Installieren
Abbildung 3.2: Bei schwereren Frequenzumrichtern ist eine Hebevorrichtung zu verwenden. Befestigen Sie zunchst die unteren beiden Schrauben an
der Wand. Heben Sie den Frequenzumrichter auf die unteren beiden Schrauben, und fixieren Sie ihn mit den oberen beiden Schrauben an der Wand.
Abmessungen, A-Gehuse
A1
A2/ A3
A5
17
3. Installieren
Gehusegre
IP
NEMA
Hhe
Hhe der Rckplatte
Hhe des Abschirmblechs
Abstand zwischen Montagelchern
Breite
20
Chassis
A2
0,25-3 kW
(200-240 V)
0,37-4,0 kW
(380-480/ 500 V)
0,75-4 kW
(525-600 V)
20
21
Chassis
Typ 1
A3
3,7 kW
(200-240 V)
5,5-7,5 kW
(380-480/ 500 V)
5,5-7,5 kW
(525-600 V)
20
21
Chassis
Typ 1
A5
0,25-3,7 kW
(200-240 V)
0,37-7,5 kW
(380-480/ 500 V)
0,75-7,5 kW
(525-600 V)
55/66
Typ 12
A
A
200 mm
316 mm
268 mm
374 mm
375 mm
268 mm
374 mm
375 mm
-
420 mm
-
190 mm
257 mm
350 mm
257 mm
350 mm
402 mm
75 mm
Breite der Rckplatte

Breite der Rckplatte mit einer
C-Option
Breite der Rckplatte mit zwei
C-Optionen
Abstand zwischen Montagelchern
Tiefe
90 mm
90 mm
130 mm
130 mm
242 mm
130 mm
130 mm
170 mm
170 mm
242 mm
150 mm
150 mm
190 mm
190 mm
242 mm
60 mm
70 mm
70 mm
110 mm
110 mm
215 mm
Tiefe ohne Option A/B
207 mm
205 mm
207 mm
205 mm
207 mm
195 mm
Mit Option A/B

Bohrungen
222 mm
220 mm
222 mm
220 mm
222 mm
195 mm
c
d
e
f
6,0 mm
8 mm
5 mm
5 mm
2,7 kg
8,0 mm
11 mm
5,5 mm
9 mm
4,9 kg
8,0 mm
11 mm
5,5 mm
9 mm
5,3 kg
8,0 mm
11 mm
5,5 mm
9 mm
6,6 kg
8,0 mm
11 mm
5,5 mm
9 mm
7,0 kg
8,25 mm
12 mm
6,5 mm
9 mm
13,5/14,2 kg
Max. Gewicht
18
A1
0,25-1,5 kW
(200-240 V)
0,37-1,5 kW
(380-480 V)
3. Installieren
Abmessungen, B-Gehuse
B1/ B2
B3
B4
Gehusegre
IP
NEMA
Hhe
Hhe der Rckplatte
Hhe des Abschirmblechs
Abstand zwischen
Montagelchern
Breite
Breite der Rckplatte mit einer COption
Breite der Rckplatte mit zwei COptionen
Abstand zwischen
Montagelchern
Tiefe
Tiefe ohne Option
A/B
Mit Option A/B
Bohrungen
Max. Gewicht
B1
5,5-7,5 kW
(200-240 V)
11-15 kW
(380-480/500 V)
11-15 kW
(525-600 V)
21/ 55/66
Typ 1/Typ 12
B2
11 kW
(200-240 V)
18,5-22 kW
(380-480/ 500 V)
18,5-22 kW
(525-600 V)
21/55/66
Typ 1/Typ 12
B3
5,5-7,5 kW
(200-240 V)
11-15 kW
(380-480/500 V)
11-15 kW
(525-600 V)
20
Chassis
B4
11-15 kW
(200-240 V)
18,5-30 kW
(380-480/ 500 V)
18,5-30 kW
(525-600 V)
20
Chassis
480 mm
650 mm
399 mm
520 mm
420 mm
595 mm
454 mm
624 mm
380 mm
495 mm
242 mm
242 mm
165 mm
230 mm
242 mm
242 mm
205 mm
230 mm
242 mm
242 mm
225 mm
230 mm
210 mm
210 mm
140 mm
200 mm
260 mm
260 mm
249 mm
242 mm
260 mm
260 mm
262 mm
242 mm
c
d
e
f
12 mm
19 mm
9 mm
9 mm
23 kg
12 mm
19 mm
9 mm
9 mm
27 kg
8 mm
12 mm
6,8 mm
7,9 mm
8,5 mm
15 mm
23,5 kg
19
3. Installieren
Abmessungen, C-Gehuse
C1/ C2
C3/ C4
20
Gehusegre
IP
NEMA
Hhe
Hhe der Rckplatte
Hhe
des
Abschirmblechs
Abstand zwischen
Montagelchern
Breite
Breite der Rckplatte mit einer COption
Breite der Rckplatte mit zwei COptionen
Abstand zwischen
Montagelchern
Tiefe
Tiefe ohne Option
A/B
Mit Option A/B
Bohrungen
Max. Gewicht
3. Installieren
C1
15-22 kW
(200-240 V)
30-45 kW
(380-480/ 500 V)
30-45 kW
(525-600 V)
21/55/66
Typ 1/Typ 12
C2
30-37 kW
(200-240 V)
55-75 kW
(380-480/ 500 V)
55-90
kW (525-600 V)
21/55/66
Typ 1/Typ 12
C3
18,5-22 kW
(200-240 V)
37-45 kW
(380-480/ 500 V)
37-45 kW
(525-600 V)
20
Chassis
C4
30-37 kW
(200-240 V)
55-75 kW
(380-480/ 500 V)
55-90 kW
(525-600 V)
20
Chassis
680 mm
770 mm
550 mm
660 mm
630 mm
800 mm
A
a
648 mm
739 mm
521 mm
631 mm
308 mm
370 mm
308 mm
370 mm
308 mm
370 mm
308 mm
370 mm
308 mm
370 mm
308 mm
370 mm
272 mm
334 mm
270 mm
330 mm
310 mm
335 mm
333 mm
333 mm
310 mm
335 mm
333 mm
333 mm
c
d
e
f
12 mm
19 mm
9,8 mm
17,6 mm
43 kg
12 mm
19 mm
9,8 mm
18 mm
61 kg
8,5 mm
17 mm
35 kg
8,5 mm
17 mm
50 kg
3.3. Elektrische Installation

ACHTUNG!
Allgemeiner Hinweis zu Kabeln
Befolgen Sie stets die nationalen und rtlichen Vorschriften zum Kabelquerschnitt und zur Umgebungstemperatur. Verwenden Sie nach
Mglichkeit Kupferleiter (60/75C).
Aluminiumleiter
Klemmen knnen zwar Aluminiumleiter aufnehmen, aber die Leiteroberflche muss sauber sein, und die Oxidation muss vor Anschluss des Leiters durch
neutrales, surefreies Vaselinefett beseitigt und die Verbindung abgedichtet werden.
Auerdem muss die Klemmenschraube nach zwei Tagen angezogen werden. Der Anschluss muss unbedingt gasdicht gehalten werden, um ein erneutes
Oxidieren der Aluminiumoberflche zu verhindern.
21
3. Installieren
Anzugsdrehmoment
Gehuse
200 - 240 V
A1
0,25-1,5 kW
A2
0,25-2,2 kW
A3
3-3,7 kW
A5
3-3,7 kW
B1
5,5-7,5 kW
B2
B3
B4
C1
C2
C3
C4
11 kW
5,5-7,5 kW
11-15 kW
15-22 kW
30-37 kW
18,5-22 kW
37-45 kW
380 - 500 V
0,37-1,5 kW
0,37-4 kW
5,5-7,5 kW
5,5-7,5 kW
11-15 kW
525 - 690 V
0,75-4 kW
5,5-7,5 kW
0,75-7,5 kW
-
18,5-22 kW
11-15 kW
18,5-30 kW
30-45 kW
55-75 kW
30-37 kW
55-75 kW
Kabel fr:
Anzugsdrehmoment
Netz, Bremswiderstand, Zwischenkreiskopp- 0,5-0,6 Nm
lung, Motorkabel
Netz, Bremswiderstand, Zwischenkreiskopplung, Motorkabel

Relais
Erde
Netz, Bremswiderstand, Zwischenkreiskopplung
Motorkabel
Relais
Erde
Relais
Erde
Relais
Erde
Motorkabel
Relais
Erde
1,8 Nm

Motorkabel
Relais
Erde
Relais
Erde
Netz, Motorkabel
14 Nm
Zwischenkreiskopplung, Bremskabel
Relais
Erde
0,5-0,6 Nm
2-3 Nm
4,5 Nm
4,5 Nm
0,5-0,6 Nm
2-3 Nm
1,8 Nm
0,5-0,6 Nm
2-3 Nm
4,5 Nm
0,5-0,6 Nm
2-3 Nm
10 Nm
10 Nm
0,5-0,6 Nm
2-3 Nm
10 Nm
0,5-0,6 Nm
2-3 Nm
10 Nm
0,5-0,6 Nm
2-3 Nm
14 Nm (bis 95 mm2)
24 Nm (ber 95 mm2)
14 Nm
0,5-0,6 Nm
2-3 Nm
3.3.1. Ausbrechen von zustzlichen ffnungen fr Kabeldurchfhrungen

1.
Entfernen Sie die Kabeleinfhrung vom Frequenzumrichter (es drfen beim ffnen der Aussparungen keine Fremdkrper in den Frequenzum-
2.
Die Kabeleinfhrung muss rund um die zu ffnende Aussparung abgesttzt werden.
3.
Die Aussparung kann nun mit einem starken Dorn und Hammer ausgeschlagen werden.
4.
Das Loch entgraten.
5.
Kabeldurchfhrung wieder am Frequenzumrichter befestigen.
richter gelangen).
3.3.2. Netzanschluss und Erdung
ACHTUNG!
Der Netzanschluss ist steckbar und an Frequenzumrichtern fr eine Leistung von bis zu 7,5 kW ausgelegt.
22
3. Installieren
1.
Befestigen Sie zuerst die beiden Schrauben am Abschirmblech, schieben Sie dieses auf, und ziehen Sie die Schrauben fest.
2.
Stellen Sie sicher, dass der Frequenzumrichter korrekt geerdet ist. Schlieen Sie den Frequenzumrichter an den Erdanschluss an (Klemme 95).
Verwenden Sie hierzu die mitgelieferte Schraube.
3.
Stecken Sie den Netzanschlussstecker (91 (L1), 92 (L2) und 93 (L3)) auf die Klemmen mit der Bezeichnung MAINS unten am Frequenzumrichter.
4.
Schlieen Sie die Netzphasen an den mitgelieferten Netzanschlussstecker an.
5.
Befestigen Sie das Kabel mit den mitgelieferten Halterungen.
ACHTUNG!
Stellen Sie sicher, dass die Netzspannung der auf dem Typenschild angegebenen Nennspannung entspricht.
IT-Netz
Schlieen Sie 400-V-Frequenzumrichter mit EMV-Filtern nicht an ein Stromnetz mit einer Spannung zwischen Phase und Erde von mehr
als 440 V an.
Der Querschnitt des Erdungskabels muss mindestens 10 mm2 betragen, oder es mssen zwei getrennt verlegte und gem EN 50178
angeschlossene Erdleitungen verwendet werden.
Bei Varianten mit Hauptschalter ist dieser auf der Netzseite vorverdrahtet.
Netzanschluss fr Gehuse A1, A2 und A3:
Netzanschluss fr A5-Gehuse (IP 55/66)
Bei Verwendung eines Trennschalters (A5-Gehuse) muss der Erdungsanschluss links im Frequenzumrichter erfolgen.
23
130BA725.10
3. Installieren
3
Abbildung 3.3: Netzanschluss bei B1- und B2-Gehusen (IP21/NEMA
Typ 1 und IP55/66/NEMA Typ 12).
130BA714.10
Abbildung 3.4: Netzanschluss B3-Gehuse (IP20).
Abbildung 3.5: Netzanschluss B4-Gehuse (IP20).
Abbildung 3.6: Netzanschluss C1- und C2-Gehuse (IP 21/ NEMA Typ
Abbildung 3.7: Netzanschluss C3-Gehuse (IP20).
130BA719.10
130BA718.10
1 und IP 55/66/ NEMA Typ 12).
Abbildung 3.8: Netzanschluss C4-Gehuse (IP20).
In der Regel werden ungeschirmte Kabel als Leistungskabel verwendet.
24
3. Installieren
3.3.3. Motoranschluss
ACHTUNG!
Das Motorkabel muss abgeschirmt sein. Bei Verwendung eines nicht abgeschirmten Kabels werden einige EMV-Anforderungen nicht
erfllt. Verwenden Sie ein abgeschirmtes Motorkabel, um die Anforderungen der EMV-Richtlinie einzuhalten. Nhere Informationen
finden Sie unter EMV-Prfergebnisse.
Hinweise zu korrekten Maen von Motorkabelquerschnitt und -lnge finden Sie im Kapitel Allgemeine technische Daten.
Abschirmung von Kabeln: Vermeiden Sie verdrillte Schirmenden (Pigtails), die hochfrequent nicht ausreichend wirksam sind. Wenn der Kabelschirm
unterbrochen werden muss (z. B. um ein Motorschtz oder einen Reparaturschalter zu installieren), muss die Abschirmung an der Unterbrechung mit der
geringstmglichen HF-Impedanz fortgefhrt werden (groflchige Schirmauflage).
Schlieen Sie den Motorkabelschirm am Schirmblech des Frequenzumrichters und am Metallgehuse des Motors an.
Stellen Sie die Schirmungsverbindungen mit einer mglichst groen Kontaktflche (Schirmbgel) her. Dies kann unter Verwendung des im Lieferumfang
des Frequenzumrichters enthaltenen Zubehrs erfolgen.
Wenn der Kabelschirm unterbrochen werden muss (z. B. um ein Motorschtz oder ein Motorrelais zu installieren), muss die Abschirmung hinter der
Unterbrechung mit der geringstmglichen HF-Impedanz fortgefhrt werden.
Kabellnge und -querschnitt: Der Frequenzumrichter ist mit einer bestimmten Kabellnge und einem bestimmten Kabelquerschnitt getestet worden.
Wird der Kabelquerschnitt erhht, so erhht sich auch der kapazitive Widerstand des Kabels und damit der Ableitstrom , sodass die Kabellnge dann
entsprechend verringert werden muss. Das Motorkabel muss mglichst kurz sein, um Rauschen und Ableitstrme auf ein Minimum zu beschrnken.
Taktfrequenz: Wenn der Frequenzumrichter zusammen mit einem Sinusfilter verwendet wird, um z. B. die Strgerusche des Motors zu reduzieren,
muss die Taktfrequenz in Parameter 14-01 entsprechend der Angabe zu dem verwendeten Sinusfilter eingestellt werden.
1.
Montieren Sie das Abschirmblech unten am Frequenzumrichter mit den Schrauben und Unterlegscheiben aus dem Montagezubehr.
2.
Schlieen Sie die drei Phasen des Motorkabels an den Klemmen 96 (U), 97 (V), 98 (W) an.
3.
Schlieen Sie den PE-Leiter mit der passenden Schraube aus dem Zubehr an Klemme 99 auf dem Abschirmblech an.
4.
Stecken Sie die Motor-Anschlussstecker mit den Klemmen 96 (U), 97 (V) und 98 (W) auf die Klemmen mit der Bezeichnung MOTOR (bis 7,5
kW).
5.
Befestigen Sie das abgeschirmte Kabel mit Schrauben und Unterlegscheiben aus dem Montagezubehr am Abschirmblech.
Alle dreiphasigen Standard-Asynchronmotoren knnen an den Frequenzumrichter angeschlossen werden. Normalerweise wird fr kleine Motoren Sternschaltung verwendet (230/400 V, Y), Grere Motoren sind in der Regel mit Dreieckschaltung angeschlossen (400/690 V, ). Schaltungsart (Stern/
Dreieck) und Anschlussspannung sind auf dem Motortypenschild angegeben.
Abbildung 3.10: Motoranschluss fr A5-Gehuse (IP 55/66/NEMA Typ

Abbildung 3.9: Motoranschluss fr A1, A2 und A3
12)
25
130BA726.10
3. Installieren
3
Abbildung 3.11: Motoranschluss fr B1- und B2-Gehuse (IP 21/NEMA
Typ 1, IP 55/NEMA Typ 12 und IP66/NEMA Typ 4X)
130BA721.10
Abbildung 3.12: Motoranschluss fr Gehuse B3.
130BA740.10
Abbildung 3.13: Motoranschluss fr Gehuse B4.
Abbildung 3.15: Motoranschluss fr Gehuse C3 und C4.
Abbildung 3.14: Motoranschluss fr C1 und C2-Gehuse (IP 21/NEMA

Typ 1 und IP 55/66/NEMA Typ 12)
26
3. Installieren
Abbildung 3.18: Kabeleinfhrungsffnungen fr Gehuse C1. Die vorAbbildung 3.16: Kabeleinfhrungsffnungen fr Gehuse B1. Die vor-
geschlagene Verwendung der Lcher ist eine reine Empfehlung, und es
sind andere Lsungen mglich.
Abbildung 3.19: Kabeleinfhrungsffnungen fr Gehuse C2. Die vorAbbildung 3.17: Kabeleinfhrungsffnungen fr Gehuse B2. Die vor-
Klemme Nr.
96
U
97
V
98
W
U1
W2
U1
V1
U2
V1
W1
V2
W1
99
PE1)
PE1)
PE1)
Motorspannung 0-100 % der Netzspannung

(Anschlussklemmen am FC 300)
Dreieckschaltung
Anschlussklemmen am Motor
Sternschaltung (U2, V2, W2)
U2, V2, W2 sind miteinander zu verbinden.
1)Schutzleiteranschluss
ACHTUNG!
Bei Motoren ohne Phasentrennpapier oder eine geeignete Isolation, welche fr den Betrieb an einem Zwischenkreisumrichter bentigt wird, muss ein LC-Filter
am Ausgang des Frequenzumrichters vorgesehen werden.
27
3. Installieren
3.3.4. Sicherungen
Abzweigschutz:
Zum Schutz der Anlage vor elektrischen Gefahren und Brnden mssen alle Abzweige in einer Installation, Schaltvorrichtungen, Maschinen usw. in
bereinstimmung mit den nationalen/internationalen Vorschriften mit einem Kurzschluss- und berstromschutz versehen sein.
Kurzschluss-Schutz:
Der Frequenzumrichter muss gegen Kurzschluss abgesichert werden, um elektrische Gefahren und ein Brandrisiko zu vermeiden. Danfoss empfiehlt die
im Folgenden aufgefhrten Sicherungen, um das Bedienpersonal und die Installation im Fall einer internen Funktionsstrung im Frequenzumrichter zu
schtzen. Der FC 300 selbst gewhrleistet einen vollstndigen Kurzschluss-Schutz am Motorausgang.
berstromschutz:
Fr einen berlastschutz ist zu sorgen, um eine Brandgefahr wegen berhitzung der Kabel in der Anlage auszuschlieen. Der Frequenzumrichter verfgt
ber einen internen berstromschutz, der als berlastschutz zwischen FC 300 und Motor verwendet werden kann (nicht UL/cUL-zugelassen). Siehe Par.
4-18. Auerdem knnen Sicherungen oder Trennschalter als berstromschutz in der Anlage verwendet werden. berstromschutz muss stets gem den
nationalen Vorschriften ausgefhrt werden.
Die Sicherungen mssen fr einen Kurzschlussstrom von max. 100.000 Arms (symmetrisch) bei 500 V ausgelegt sein.
Keine UL-Konformitt
Wenn keine bereinstimmung mit UL/cUL-Zulassung bestehen muss, knnen die nebenstehenden Sicherungen in bereinstimmung mit EN50178 verwendet werden.
Die Nichtbeachtung dieser Empfehlung kann im Fall einer Fehlfunktion zu unntiger Beschdigung des Frequenzumrichters fhren.
FC 300
K25-K75
1K1-2K2
3K0-3K7
5K5-7K5
11K
Max. Sicherungsgre1)
10A
20A
32A
63A
80A
15K-18K5
22K
30K
37K
125A
160A
200A
250A
Spannung
200-240 V
200-240 V
200-240 V
380-500 V
380-500 V
Typ
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
380-500
380-500
380-500
380-500
Typ gG
Typ aR
Typ aR
Typ aR
V
V
V
V
1) Max. Sicherungen siehe nationale/internationale Vorschriften zur Auswahl einer geeigneten Sicherungsgre.
FC 300
K37-1K5
2K2-4K0
5K5-7K5
11K-18K
22K
30K
37K
45K
55K-75K
28
Max. Sicherungsgre1)
10A
20A
32A
63A
80A
100A
125A
160A
250A
Spannung
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
380-500 V
Typ
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
Typ gG
Typ aR
Typ aR
3. Installieren
UL-Konformitt
200-240 V
FC 300
kW
K25-K37
K55-1K1
1K5
2K2
3K0
3K7
5K5
7K5
11K
15K-18K5
Bussmann
Typ RK1
KTN-R05
KTN-R10
KTN-R15
KTN-R20
KTN-R25
KTN-R30
KTN-R50
KTN-R60
KTN-R80
KTN-R125
FC 300
kW
K25-K37
K55-1K1
1K5
2K2
3K0
3K7
5K5
7K5
11K
15K-18K5
FC 300
kW
22K
30K
37K
Bussmann
Typ J
JKS-05
JKS-10
JKS-15
JKS-20
JKS-25
JKS-30
KS-50
JKS-60
JKS-80
JKS-150
Bussmann
Typ T
JJN-06
JJN-10
JJN-15
JJN-20
JJN-25
JJN-30
JJN-50
JJN-60
JJN-80
JJN-125
SIBA
Littelfuse
Typ RK1
5017906-005
5017906-010
5017906-016
5017906-020
5017906-025
5012406-032
5014006-050
5014006-063
5014006-080
2028220-125
Typ RK1
KLN-R05
KLN-R10
KLN-R15
KLN-R20
KLN-R25
KLN-R30
KLN-R50
KLN-R60
KLN-R80
KLN-R125
Bussmann
Typ CC
FNQ-R-5
FNQ-R-10
FNQ-R-15
FNQ-R-20
FNQ-R-25
FNQ-R-30
-
Bussmann
Typ CC
KTK-R-5
KTK-R-10
KTK-R-15
KTK-R-20
KTK-R-25
KTK-R-30
-
FerrazShawmut
Typ CC
ATM-R05
ATM-R10
ATM-R15
ATM-R20
ATM-R25
ATM-R30
-
Bussmann
SIBA
Littelfuse
Type JFHR2
FWX-150
FWX-200
FWX-250
Typ RK1
2028220-150
2028220-200
2028220-250
JFHR2
L25S-150
L25S-200
L25S-250
Bussmann
Typ CC
LP-CC-5
LP-CC-10
LP-CC-15
LP-CC-20
LP-CC-25
LP-CC-30
-
FerrazShawmut
Typ RK1
A2K-05R
A2K-10R
A2K-15R
A2K-20R
A2K-25R
A2K-30R
A2K-50R
A2K-60R
A2K-80R
A2K-125R
FerrazShawmut
JFHR2
A25X-150
A25X-200
A25X-250
KTS-Sicherungen von Bussmann knnen KTN-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.

FWH-Sicherungen von Bussmann knnen FWX-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
KLSR-Sicherungen von LITTELFUSE knnen KLNR-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
L50S-Sicherungen von LITTELFUSE knnen L50S-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
A6KR-Sicherungen von FERRAZ-SHAWMUT knnen A2KR-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
A50X-Sicherungen von FERRAZ-SHAWMUT knnen A25X-Sicherungen bei 240-V-Frequenzumrichtern ersetzen.
380-500 V
FC 300
kW
K37-1K1
1K5-2K2
3K0
4K0
5K5
7K5
11K
15K
18K
22K
30K
37K
45K
Bussmann
Typ RK1
KTS-R6
KTS-R10
KTS-R15
KTS-R20
KTS-R25
KTS-R30
KTS-R40
KTS-R50
KTS-R60
KTS-R80
KTS-R100
KTS-R125
KTS-R150
Bussmann
Typ J
JKS-6
JKS-10
JKS-15
JKS-20
JKS-25
JKS-30
JKS-40
JKS-50
JKS-60
JKS-80
JKS-100
JKS-150
JKS-150
Bussmann
Typ T
JJS-6
JJS-10
JJS-15
JJS-20
JJS-25
JJS-30
JJS-40
JJS-50
JJS-60
JJS-80
JJS-100
JJS-150
JJS-150
Bussmann
Typ CC
FNQ-R-6
FNQ-R-10
FNQ-R-15
FNQ-R-20
FNQ-R-25
FNQ-R-30
-
Bussmann
Typ CC
KTK-R-6
KTK-R-10
KTK-R-15
KTK-R-20
KTK-R-25
KTK-R-30
-
Bussmann
Typ CC
LP-CC-6
LP-CC-10
LP-CC-15
LP-CC-20
LP-CC-25
LP-CC-30
-
29
3. Installieren
FC 300
kW
K37-1K1
1K5-2K2
3K0
4K0
5K5
7K5
11K
15K
18K
22K
30K
37K
45K
FC 300
kW
55K
75K
SIBA
Littelfuse
Typ RK1
5017906-006
5017906-010
5017906-016
5017906-020
5017906-025
5012406-032
5014006-040
5014006-050
5014006-063
2028220-100
2028220-125
2028220-125
2028220-160
Typ RK1
KLS-R6
KLS-R10
KLS-R15
KLS-R20
KLS-R25
KLS-R30
KLS-R40
KLS-R50
KLS-R60
KLS-R80
KLS-R100
KLS-R125
KLS-R150
Bussmann
JFHR2
FWH-200
FWH-250
FC 300
kW
55K
75K
Bussmann
Typ H
-
SIBA
Littelfuse
Typ RK1
2028220-200
2028220-250
JFHR2
L50S-225
L50S-250
FerrazShawmut
Typ CC
ATM-R6
ATM-R10
ATM-R15
ATM-R20
ATM-R25
ATM-R30
-
FerrazShawmut
Typ RK1
A6K-6R
A6K-10R
A6K-15R
A6K-20R
A6K-25R
A6K-30R
A6K-40R
A6K-50R
A6K-60R
A6K-80R
A6K-100R
A6K-125R
A6K-150R
Bussmann
Typ T
-
Bussmann
JFHR2
-
FerrazShawmut
JFHR2
-
FerrazShawmut
JFHR2
A50-P225
A50-P250
A50QS-Sicherungen von Ferraz-Shawmut knnen durch A50P-Sicherungen ausgetauscht werden.

Abgebildete 170M-Sicherungen von Bussman verwenden den optischen Kernmelder -/80. Sicherungen TN/80 Typ T, -/110 oder TN/110 Typ
T mit Kernmelder der gleichen Gre und Amperezahl knnen ausgetauscht werden.
550 - 600V
FC 300
kW
K75-1K5
2K2-4K0
5K5-7K5
FC 300
Bussmann
Typ RK1
KTS-R-5
KTS-R10
KTS-R20
Bussmann
Typ J
JKS-5
JKS-10
JKS-20
Bussmann
Typ T
JJS-6
JJS-10
JJS-20
Bussmann
Typ CC
FNQ-R-5
FNQ-R-10
FNQ-R-20
SIBA
Littelfuse
kW
K75-1K5
2K2-4K0
5K5-7K5
Typ RK1
5017906-005
5017906-010
5017906-020
Typ RK1
KLSR005
KLSR010
KLSR020
FC 300
Bussmann
SIBA
kW
P37K
P45K
P55K
P75K
JFHR2
170M3013
170M3014
170M3015
170M3015
Typ RK1
2061032.125
2061032.160
2061032.200
2061032.200
Bussmann
Typ CC
KTK-R-5
KTK-R-10
KTK-R-20
Bussmann
Typ CC
LP-CC-5
LP-CC-10
LP-CC-20
FerrazShawmut
Typ RK1
A6K-5R
A6K-10R
A6K-20R
FerrazShawmut
Typ RK1
6.6URD30D08A0125
6.6URD30D08A0160
6.6URD30D08A0200
6.6URD30D08A0200
Abgebildete 170M-Sicherungen von Bussman verwenden den optischen Kernmelder -/80. Sicherungen TN/80 Typ T, -/110 oder TN/110 Typ
T mit Kernmelder der gleichen Gre und Amperezahl knnen ausgetauscht werden.
Bei 170M-Sicherungen von Bussmann in den Frequenzumrichtern 525-600/690 V FC-302 P37K-P75K, FC-102 P75K oder FC-202 P45K-P90K
handelt es sich um Sicherungen des Typs 170M3015.
Bei 170M-Sicherungen von Bussmann in den Frequenzumrichtern 525-600/690V FC-302 P90K-P132, FC-102 P90K-P132 oder FC-202 P110-P160
Bei 170M-Sicherungen von Bussmann in den Frequenzumrichtern 525-600/690V FC302 P160-P315, FC-102 P160-P315 oder FC-202 P200-P400
30
3. Installieren
3.3.5. Zugang zu den Steuerklemmen

Alle Klemmen zu den Steuerkabeln befinden sich unter der Klemmenabdeckung vorn auf dem Frequenzumrichter. Entfernen sie diese Klemmenabdeckung mit Hilfe eines Schraubendrehers.
Abbildung 3.20: Zugriff auf Steuerklemmen in den Gehusen A2, A3,

B3, B4, C3 und C4.
Nehmen Sie die vordere Abdeckung ab. Achten Sie beim Wiederanbringen der Abdeckung auf die richtige Befestigung mit einem Drehmoment
von 2 Nm.
Abbildung 3.21: Zugriff auf Steuerklemmen in den Gehusen A5, B1,B2,

C1 und C2.
31
3. Installieren
3.3.6. Elektrische Installation, Steueranschlsse
Befestigen des Kabels in der Federzugklemme:
1.
Kabel 9-10 mm abisolieren.
2.
Fhren Sie einen Schraubendreher1) in die rechteckige ffnung ein, und ffnen Sie die Klemmfeder.
3.
Kabel in die runde Klemmffnung einfhren.
4.
Schraubendreher herausziehen. Das Kabel ist nun an der Klemme befestigt.
Entfernen des Kabels aus der Federzugklemme:
1)
1.
Fhren Sie einen Schraubendreher1) in die rechteckige ffnung ein, und ffnen Sie die Klemmfeder.
2.
Kabel herausziehen.
Max. 0,4 x 2,5 mm
1.
2.
32
3.
3. Installieren
3.4. Anschlussbeispiele
3.4.1. Start/Stopp
Klemme 18 = Par. 5-10 [8] Start
Klemme 27 = Par. 5-12 [0] Ohne Funktion (Standardeinstellung Motor-
freilauf (inv.))
Klemme 37 = Sicherer Stopp (wenn verfgbar!)
3.4.2. Puls Start/Stopp

Klemme 18 = Par. 5-10 [9] Puls-Start
Klemme 27= Par. 5-12 [6] Stopp (invers)
Klemme 37 = Sicherer Stopp (wenn verfgbar!)
33
3. Installieren
3.4.3. Drehzahl auf/ab
Klemmen 29/32 = Drehzahlkorrektur auf/ab:
Klemme 18 = Par. 5-10 [9] Start (Standard)
Klemme 27 = Par. 5-12 [19] Sollw. speich.
Klemme 29 = Par. 5-13 [21] Drehzahl auf
Klemme 32 = Par. 5-14 [22] Drehzahl ab

Hinweis: Klemme 29 nur bei FC x02 (x=Serie).
3.4.4. Potentiometer-Sollwert
Spannungssollwert ber Potentiometer:
Variabler Sollwert 1 = [1] Analogeingang 53 (Standard)
Klemme 53 Skal. Min. Spannung = 0 Volt
Klemme 53 Skal. Max. Spannung = 10 Volt
Klemme 53, Skal. Min.-Soll/Istwert = 0 UPM
Klemme 53, Skal. Max.-Soll/Istwert = 1500 UPM
Schalter S201 = AUS (U)
34
3. Installieren
3.5.1. Elektrische Installation, Steuerkabel
Abbildung 3.22: bersicht ber smtliche Klemmen (ohne Optionen).

Klemme 37 ist der Eingang, der fr die Funktion Sicherer Stopp verwendet wird. Der Abschnitt Sicheren Stopp installieren im Projektierungshandbuch
enthlt Anweisungen zu dieser Installation.
* Klemme 37 ist beim FC 301 nicht verfgbar (Ausnahme: FC 301 A1).
Klemme 29 und Relais 2 sind im Lieferumfang des FC 301 nicht enthalten.
Sehr lange Steuerkabel und Analogsignale knnen in seltenen Fllen und je nach Installation infolge von Rauschen von den Netzstromkabeln zu 50/60
Hz-Brummschleifen fhren.
In diesem Fall sollte getestet werden, ob durch einseitiges Auflegen des Kabelschirms bzw. durch Verbinden des Kabelschirms ber einen 100-nF-Kondensator mit Masse eine Besserung herbeigefhrt werden kann.
Die Digital- und Analogein- und -ausgnge mssen getrennt an die Gleichtakteingnge des Frequenzumrichters (Klemme 20, 55, 39) angeschlossen
werden, damit Erdstrme von beiden Gruppen die anderen Gruppen nicht beeintrchtigen. Beispielsweise kann Einschalten des Digitaleingangs das
analoge Eingangssignal stren.
35
3. Installieren
Eingangspolaritt der Steuerklemmen
130BA681.10
ACHTUNG!
Steuerkabel mssen abgeschirmt sein.
Hinweise zur richtigen Terminierung von Steuerkabeln finden Sie im Abschnitt Erdung abgeschirmter Steuerkabel.
130BA681.10
3.5.2. Schalter S201, S202 und S801

Die Schalter S201 (A53) und S202 (A54) dienen dazu, die Betriebsart fr Strom (0-20 mA) oder Spannung (-10 bis 10 V) fr die Analogeingnge 53 bzw.
54 auszuwhlen.
Schalter S801 (BUS TER.) kann benutzt werden, um fr die serielle RS-485-Schnittstelle (Klemmen 68 und 69) die integrierten Busabschlusswiderstnde
zu aktivieren.
Siehe auch das Diagramm mit allen elektrischen Anschlssen im Abschnitt Elektrische Installation.
Werkseinstellung:
S201 (A53) = AUS (Spannungseingang)
S202 (A54) = AUS (Spannungseingang)
S801 (Busterminierung) = AUS
36
3. Installieren
Beim ndern der Funktion der Schalter S201, S202 und

S801 darf ein Umschalten nicht mit Gewalt herbeigefhrt werden. Nehmen Sie beim Bedienen der Schalter
vorsichtshalber die LCP-Bedieneinheit ab. Die Schalter
drfen nur bettigt werden, wenn der Frequenzumrichter spannungsfrei geschaltet ist.
37
3. Installieren
3.6.1. Erste Inbetriebnahme und Test
Um die Konfiguration zu testen und sicherzustellen, dass der Frequenzumrichter funktioniert, kann folgendermaen vorgegangen werden:
Schritt 1. berprfen Sie das Motor-Typenschild.

ACHTUNG!
Der Motor hat entweder Sternschaltung (Y) oder Dreieckschaltung (). Diese Informationen befinden sich
auf dem Typenschild.
Schritt 2. Geben Sie die Motor-Typenschilddaten in der folgenden Reihenfolge in die entsprechenden Parameter ein.
Um diese Liste aufzurufen, drcken Sie erst die Taste [QUICK MENU] und
whlen Sie dann Q2 Quick Setup (Inbetriebnahme-Men).
1.
2.
3.
4.
5.
Motornennleistung [kW]
oder Motornennleistung [PS]
Motornennspannung
Motornennfrequenz
Motornennstrom
Motornenndrehzahl
Par.
Par.
Par.
Par.
Par.
Par.
1-20
1-21
1-22
1-23
1-24
1-25
Schritt 3. Aktivieren Sie die Automatische Motoranpassung

(AMA).
Die Ausfhrung einer AMA stellt die optimale Motorleistung sicher. Bei der AMA werden exakt die elektrischen Ersatzschaltbilddaten
des Motors gemessen und die interne Regelung optimiert.
1.
Schlieen Sie Klemme 37 an Klemme 12 an (falls Klemme 37 verfgbar ist).
2.
Schlieen Sie Klemme 27 an Klemme 12 an, oder setzen Sie Par. 5-12 auf Ohne Funktion (Par. 5-12 [0]).
3.
Aktivieren Sie die AMA in Par. 1-29
4.
Aktivieren Sie die AMA. Ist ein Sinusfilter vorhanden, darf nur die reduzierte AMA ausgefhrt werden. Andernfalls ist das Sinusfilter whrend der
AMA zu entfernen.
5.
Drcken Sie die [OK]-Taste. Im Display wird AMA mit [Hand on]-Taste starten angezeigt.
6.
Drcken Sie die [Hand on]-Taste. Ein Statusbalken stellt den Verlauf der AMA dar.
AMA-Ausfhrung vorzeitig abbrechen

1.
Drcken Sie die [OFF]-Taste: der Frequenzumrichter zeigt einen Alarm an, und am Display wird gemeldet, dass die AMA durch den Benutzer
abgebrochen wurde.
38
3. Installieren
Erfolgreiche AMA
1.
Im Display wird AMA mit [OK]-Taste beenden angezeigt.
2.
Drcken Sie die [OK]-Taste, um die automatische Motoranpassung abzuschlieen.
Fehlgeschlagene AMA
1.
Der Frequenzumrichter zeigt einen Alarm an. Eine Beschreibung des Alarms finden Sie im Abschnitt Warnungen und Alarme.
2.
Wert im Fehlerspeicher ([Alarm Log]-Taste) zeigt die zuletzt vor dem Alarm von der AMA ausgefhrte Messsequenz. Diese Nummer zusammen
mit der Beschreibung des Alarms hilft Ihnen bei der Fehlersuche. Geben Sie die Nummer und die Beschreibung des Alarms bei eventuellen
Anrufen beim Danfoss-Service an.

ACHTUNG!
Hufige Ursache fr eine fehlgeschlagene AMA sind falsch registrierte Motor-Typenschilddaten oder auch eine zu groe Differenz
zwischen Umrichter-/Motor-Nennleistung.
Schritt 4. Drehzahlgrenze und Rampenzeit einstellen

Minimaler Sollwert
Max. Sollwert
Par. 3-02
Par. 3-03
Tabelle 3.3: Stellen Sie die Grenzwerte fr Drehzahl und Rampenzeit

gem den Anforderungen ein.
Min. Drehzahl
Max. Drehzahl
Par. 4-11 bzw. 4-12

Par. 4-13 bzw. 4-14
Rampenzeit Auf 1
Rampenzeit Ab 1
Par. 3-41
Par. 3-42
39
3. Installieren
3.7. Zustzliche Verbindungen

3.7.1. Mechanische Bremssteuerung
In Hub- und Vertikalfrderanwendungen muss in der Regel eine elektromechanische Bremse gesteuert werden:
Verwenden Sie zum Steuern der Bremse einen Relais- oder Digitalausgang (Klemme 27 und 29).
Halten Sie den Ausgang geschlossen (spannungsfrei), so lange der Frequenzumrichter den Motor nicht halten kann, da z. B. die Last zu schwer
ist.
Whlen Sie Mechanische Bremse [32] in Par. 5-4* fr Anwendungen mit einer elektromechanischen Bremse.
Die Bremse wird gelst, wenn der Motorstrom den in Par. 2-20 eingestellten Wert berschreitet.
Die Bremse wird bettigt, wenn die Ausgangsfrequenz niedriger ist als die in Par. 2-21 bzw. 2-22 eingestellte Frequenz und ein Stoppbefehl
anliegt.
Beim Auftreten eines Alarms fllt die mechanische Bremse sofort ein. Siehe auch Abschnitt Ansteuerung der mechanischen Bremse im Kapitel Einfhrung
zum FC 300.
3.7.2. Parallelschaltung von Motoren

Der Frequenzumrichter kann mehrere parallel geschaltete Motoren steuern. Der Gesamtstrom der Motoren darf den maximalen Ausgangsnennstrom IM,N des Frequenzumrichters nicht bersteigen.
ACHTUNG!
Installationen mit gemeinsamem Anschluss wie in der
Abbildung unten werden nur bei kurzen Kabeln empfohlen.
ACHTUNG!
Bei parallel geschalteten Motoren kann Par. 1-29 Au-
tomatische Motoranpassung (AMA) nicht benutzt werden.
ACHTUNG!
Das elektronisch thermische Relais (ETR) des Frequenzumrichters kann bei parallel geschalteten Motoren
nicht als Motor-berlastschutz fr die einzelnen Motoren des Systems verwendet werden. Ein zustzlicher
Motorschutz, z. B. Thermistoren oder Thermorelais
sind deshalb vorzusehen (Motorschutzschalter sind als
Schutz nicht geeignet).
Beim Start und bei niedrigen Drehzahlen knnen mglicherweise Probleme auftreten, wenn die Motorgren sehr unterschiedlich sind, da bei kleinen
Motoren der relativ hohe ohmsche Widerstand im Stator eine hhere Spannung beim Start und bei niedrigen Drehzahlen erfordert.
3.7.3. Thermischer Motorschutz

Das elektronisch thermische Relais im Frequenzumrichter hat die UL-Zulassung fr Einzelmotorschutz, wenn Par. 1-90 Thermischer Motorschutz auf ETR-
Alarm und Par. 1-24 Motorstrom, IM,N auf Motornennstrom (siehe Motor-Typenschild) eingestellt ist.
Als thermischer Motorschutz kann ebenfalls die PTC-Thermistorkartenoption MCB 112 verwendet werden. Diese Karte ist ATEX-zertifiziert fr den Schutz
von Motoren in explosionsgefhrdeten Bereichen, Zone 1/21 und Zone 2/22. Weitere Informationen siehe Projektierungshandbuch.
40
4. Programmieren
4. Programmieren
4.1. Die grafische und numerische Bedieneinheit
Am einfachsten lsst sich der Frequenzumrichter ber die grafische Bedieneinheit (LCP 102) programmieren. Bei Verwendung der numerischen Bedieneinheit (LCP 101) bentigen Sie das Projektierungshandbuch des Frequenzumrichters als Referenz.
4.1.1. Programmieren an der grafischen LCP-Bedieneinheit
Die folgenden Anweisungen gelten fr das grafische LCP (LCP 102):
Die Bedieneinheit ist in vier funktionelle Gruppen unterteilt:

1.
Grafikdisplay mit Statuszeilen.
2.
Mentasten und Anzeige-LEDs zum ndern der Parameter und

zum Umschalten zwischen Displayfunktionen.
3.
Navigationstasten und Kontroll-Anzeigen (LEDs).
4.
Bedientasten mit Kontrollanzeigen (LEDs).
Alle Daten werden auf einem LCP-Grafikdisplay wiedergegeben (maximal

fnf Betriebsvariablen) [Status].
Anzeigezeilen:
a.
Statuszeile: Zustandsmeldungen in der Form von Symbolen

und Grafiken.1
b.
Zeile 1-2: Je nach Displayanzeigeart Anzeigebereich fr Betriebsvariablen oder fr Parameternavigation bzw. -nderung.
Durch Drcken der Taste [Status] kann eine zustzliche Zeile
eingefgt werden.1
c.
Statuszeile: Zustandsmeldungen in Textform.1
41
4. Programmieren
4.1.2. Programmieren an der numerischen LCP-Bedieneinheit

In den folgenden Anleitungen wird davon ausgegangen, dass eine numerische LCP-Bedieneinheit (LCP 101) angeschlossen ist:
Die Bedieneinheit ist in vier funktionelle Gruppen unterteilt:

1.
Numerisches Display.
2.
Mentasten mit Anzeige-LEDs Parameter ndern und zwischen Displayfunktionen umschalten.
42
3.
Navigationstasten und Kontroll-Anzeigen (LEDs).
4.
Bedientasten mit Kontroll-Anzeigen (LEDs).
4. Programmieren
4.1.3. Erste Inbetriebnahme

Am einfachsten lsst sich die Anlage in Betrieb nehmen, indem Sie auf die Taste [Quick Menu] drcken und die Anweisungen der grafischen Bedieneinheit
befolgen (lesen Sie die Tabelle von links nach rechts):
Drcken Sie
Q2 Quick Menu/Inbetriebnahme-Men
0-01 Language/Sprache
Legen Sie die Sprache fest.
1-20 Motornennleistung
Stellen Sie die auf dem Typenschild des Motors angegebene

Nennleistung ein.
1-22 Motornennspannung

Motornennspannung ein.
1-23 Motornennfrequenz

Motornennfrequenz ein.
1-24 Motornennstrom
Stellen Sie den auf dem Typenschild des Motors angegebenen

Motornennstrom ein.
1-25 Motornenndrehzahl

Nenndrehzahl ein.
5-12 Klemme 27 Digitaleingang
Sie knnen die Standardeinstellung fr die Klemme, Motorfreilauf (inv.), in Ohne Funktion ndern. In diesem Fall ist fr die
AMA kein Anschluss an Klemme 27 erforderlich.
1-29 Automatische Motoranpassung
Whlen Sie die gewnschte AMA-Funktion aus. Whlen Sie nach

Mglichkeit Komplette AMA.
3-02 Minimaler Sollwert
Legen Sie die Mindestdrehzahl der Motorwelle fest.
3-03 Max. Sollwert
Legen Sie die maximale Drehzahl der Motorwelle fest.
3-41 Rampenzeit Auf 1
Legen Sie die Rampenzeit Auf im Hinblick auf die Motornenndrehzahl aus Par. 1-25 fest.
3-42 Rampenzeit Ab 1
Legen Sie die Rampenzeit Ab im Hinblick auf die Motornenndrehzahl aus Par. 1-25 fest.
3-13 Sollwertvorgabe
Legen Sie fest, welcher Sollwert aktiv ist.
43
4. Programmieren
4.2. Inbetriebnahme-Men
0-01 Sprache
Option:
Funktion:
Bestimmt die im Display zu verwendende Sprache.
Der Frequenzumrichter kann mit 4 verschiedenen Sprachpaketen geliefert werden. Englisch und Deutsch sind
in allen Paketen enthalten. Englisch kann nicht gelscht oder gendert werden.
Englisch
Teil der Sprachpakete 1 - 4
[1]
Deutsch
Teil der Sprachpakete 1 - 4
[2]
Franzsisch
Teil des Sprachpakets 1
[3]
Dnisch
[4]
Spanisch
[5]
Italienisch
[6]
Schwedisch
[7]
Niederlndisch
[10]
Chinesisch
Sprachpaket 2
[20]
Finnisch
[22]
Englisch US
[27]
Griechisch
[28]
Portugiesisch
[36]
Slowenisch
[39]
Koreanisch
[40]
Japanisch
[41]
Trkisch
[42]
Chinesisch traditionell
[43]
Bulgarisch
[44]
Serbisch
[45]
Rumnisch
[46]
Ungarisch
[47]
Tschechisch
[0]
[48]
Polnisch
[49]
Russisch
[50]
Thailndisch
[51]
Indonesisch
1-20 Motornennleistung
Range:
grenabhngig*
Funktion:
[0,09 - 1200 kW] Der Wert der Motornennleistung in kW muss den Angaben auf dem Typenschild des angeschlossenen Motors
entsprechen. Die Werkseinstellung entspricht der Typenleistung des Frequenzumrichters.
Dieser Parameter kann nicht bei laufendem Motor gendert werden. Dieser Par. ist im LCP sichtbar, wenn Par.
0-03 International [0] ist.
ACHTUNG!
Vier Leistungsgren ber, eine Gre unter der VLT-Nennleistung.
44
4. Programmieren
1-22 Motornennspannung
Range:
Funktion:
Grenabhngig* [10 - 1000 V]
Der Wert muss den Angaben auf dem Typenschild des angeschlossenen Motors entsprechen. Die Werkseinstellung entspricht der Nennleistung des Frequenzumrichters.
Dieser Parameter kann nicht bei laufendem Motor gendert werden.
1-23 Motornennfrequenz
Option:
Funktion:
Min. - max. Motorfrequenz: 20 - 1000 Hz
Stellen Sie einen Wert ein, der den Angaben auf dem Typenschild des angeschlossenen Motors entspricht. Auerdem besteht die Mglichkeit einer stufenlosen Einstellung der Motorfrequenz. Wird ein Wert abweichend von
50 Hz oder 60 Hz eingestellt, so ist eine Korrektur der Parameter 1-50 bis 1-53 erforderlich. Fr 87-Hz-Betrieb
bei 230/400-V-Motoren die Typenschilddaten fr 230 V/50 Hz einstellen. Parameter 4-13 Max. Drehzahl [UPM]
und Parameter 3-03 Maximaler Sollwert mssen bei der 87-Hz-Anwendung angepasst werden.
[50]
50 Hz, wenn Par. 0-03

= International
[60]
60 Hz, wenn Par. 0-03

= US
1-24 Motornennstrom
Range:
Funktion:
Grenabhngig* [0,1 - 10000 A]
Der Wert muss den Angaben auf dem Typenschild des angeschlossenen Motors entsprechen. Diese Daten dienen
der Berechnung von Drehmoment, Motorschutz usw.
1-25 Motornenndrehzahl
Range:
Funktion:
Grenabhngig* [100 - 60.000
Der Wert muss den Angaben auf dem Typenschild des angeschlossenen Motors entsprechen. Dieser Wert dient
UPM]
zur Berechnung des optimalen Schlupfausgleichs.
5-12 Klemme 27 Digitaleingang

Option:
Funktion:
Whlen Sie die Funktion aus dem verfgbaren Digitaleingangsbereich aus.
Ohne Funktion
Reset
Motorfreilauf (inv.)
Mot.freil./Res. inv.
Schnellst.rampe (inv)
DC Bremse (invers)
Stopp (invers)
Start
Puls-Start
Reversierung
Start + Reversierung
Start nur Rechts
Start nur Links
Festdrz. (JOG)
Festsollwert Bit 0
Festsollwert Bit 1
Festsollwert Bit 2
Sollw. speich.
[0]
[1]
[2]
[3]
[4]
[5]
[6]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[16]
[17]
[18]
[19]
45
4. Programmieren
5-12 - fortgesetzt
Option:
Funktion:
Drehz. speich.
Drehzahl auf
Drehzahl ab
Satzanwahl Bit 0
Satzanwahl Bit 1
Freq.korr. Auf
Freq.korr. Ab
Pulseingabe
Rampe Bit 0
Rampe Bit 1
Netzausfall (invers)
DigiPot Auf
DigiPot Ab
DigiPot lschen
Reset Zhler A
Reset Zhler B
[20]
[21]
[22]
[23]
[24]
[28]
[29]
[32]
[34]
[35]
[36]
[55]
[56]
[57]
[62]
[65]
1-29 Autom. Motoranpassung

Option:
Funktion:
Die AMA-Funktion optimiert die dynamische Motorleistung durch automatisches Optimieren der erweiterten Motorparameter (Par. 1-30 bis Par. 1-35) im Stillstand.
Aktivieren Sie die AMA-Funktion durch Drcken von [Hand-on] nach Auswahl von [1] oder [2]. Siehe auch
Abschnitt Automatische Motoranpassung. Verluft die Motoranpassung normal, wird zum Abschluss folgende
Meldung im Display angezeigt: AMA mit [OK]-Taste beenden. Nach Drcken der [OK]-Taste ist der Frequenzumrichter wieder betriebsbereit.
[0]
Anpassung aus
[1]
Komplette Anpassung
Eine automatische Motoranpassung des Statorwiderstands RS, des Rotorwiderstands Rr, der Statorstreureaktanz X1, der Rotorstreureaktanz X2 und der Hauptreaktanz Xh wird vorgenommen.
FC 301: Die Komplette AMA umfasst beim FC 301 keine Xh-Messung, der Xh-Wert wird jedoch aus der Motordatenbank ermittelt. Par. 1-35 Hauptreaktanz (Xh) kann bei Bedarf manuell angepasst werden, um optimale
Leistung zu erreichen.
[2]
Reduz. Anpassung
Ein reduzierter Test wird durchgefhrt, bei dem nur der Statorwiderstand Rs im System ermittelt wird. Whlen
Sie diese Option, wenn ein LC-Filter zwischen Frequenzumrichter und Motor eingesetzt wird.
Hinweis:
Die AMA sollte an einem kalten Motor durchgefhrt werden.
Die AMA kann nicht durchgefhrt werden, whrend der Motor luft.
Die AMA kann nicht bei permanenterregten Motoren durchgefhrt werden.
ACHTUNG!
Zuvor mssen die Motornenndaten 1-2* vom Typenschild korrekt eingegeben werden, da sie in den AMA-Algorithmus einflieen. Fr
eine optimale dynamische Motorleistung ist eine AMA notwendig. Je nach Nennleistung des Motors kann die Motoranpassung bis zu
10 Minuten dauern.
ACHTUNG!
Whrend der AMA darf die Motorwelle nicht angetrieben werden.
ACHTUNG!
ndert sich eine der Einstellungen in Par. 1-2*, dann werden die Werkseinstellungen fr Par. 1-30 bis 1-39 wiederhergestellt. Gegebenenfalls ist eine erneute AMA notwendig.
46
4. Programmieren
3-02 Minimaler Sollwert

Range:
Funktion:
0,000 Einheit* [-100000,000 Par. Der minimale Sollwert bestimmt den Mindestwert der Summe aller Sollwerte. Der minimale Sollwert ist nur aktiv,
wenn in Parameter 3-00 die Option Min. bis Max. [0] gewhlt wurde.
3-03]
3-03 Max. Sollwert

Range:
Funktion:
1500.000* [Par. 3-02 - 100000,000] Geben Sie den maximalen Sollwert ein. Der maximale Sollwert definiert den maximalen Wert, den die Summe
aller Sollwerte annehmen kann.
Die Einheit des max. Sollwerts richtet sich nach:
der Auswahl in Par. 1-00 Regelverfahren: Mit Drehgeber [1]: UPM, Drehmomentregler [2], Nm.
der in Par. 3-01 Soll-/Istwerteinheit gewhlten Einheit.
3-41 Rampenzeit Auf 1

Range:
Funktion:
s* [0,01 - 3600,00 s]
Die Rampenzeit Auf ist die Beschleunigungszeit von 0 UPM bis zur Motornenndrehzahl nM,N (Par. 1-25), vorausgesetzt, der Ausgangsstrom erreicht nicht die Stromgrenze (eingestellt in Par. 4-18). Der Wert 0,00 entspricht
0,01 s im Drehzahlmodus. Siehe Rampenzeit Ab in Par. 3-42.
Par.. 3 41 =
tBeschl s n M , N ( Par.. 1 25) UPM

Sollw. UPM
3-42 Rampenzeit Ab 1
Range:
Funktion:
grenabhngig [0,01 - 3600,00 s]
Die Rampenzeit Ab ist die Verzgerungszeit von der Motornenndrehzahl nM,N (Par. 1-25) bis 0 UPM, vorausgesetzt, es tritt keine berspannung aufgrund von generatorischem Betrieb des Motors auf bzw. es wird nicht die
Drehmomentgrenze erreicht (eingestellt in Par. 4-18). Der Wert 0,00 entspricht 0,01 s im Drehzahlmodus. Siehe
Rampenzeit Auf in Par. 3-41.
Par.. 3 42 =
tBeschl s x nM , N ( Par.. 1 25) UPM

Sollw. UPM
47
4. Programmieren
4.3. Parameterlisten
nderungen whrend des Betriebs
TRUE (WAHR) bedeutet, dass der Parameter whrend des Betriebs des Frequenzumrichters gendert werden kann; FALSE (FALSCH) bedeutet, dass der
Frequenzumrichter gestoppt werden muss, um nderungen vorzunehmen.
4-Setup (4-Par. Stze)

'Gesamter Parametersatz': der Parameter kann einzeln in jedem der vier Parameterstze eingestellt werden, d. h., ein einzelner Parameter kann vier
verschiedene Datenwerte haben.
1-Setup (1 Parametersatz): Datenwert ist derselbe in allen Parameterstzen.
Umrechnungsindex
Diese Zahl bezieht sich auf eine Umrechnungszahl, die beim Schreiben oder Lesen mit einem Frequenzumrichter verwendet wird.
Umrechnungsindex
Umrechnungsfaktor
Datentyp
2
3
4
5
6
7
9
33
35
54
100
67
1/60
1000000 100000
-1
-2
10000
1000
100
10
0.1
0.01
Beschreibung
Integer (Ganzzahl) 8 Bit
Ohne Vorzeichen 8
Ohne Vorzeichen 16 Bit
Ohne Vorzeichen 32 Bit
Sichtbarer String
Nennwert 2 Byte
Bitsequenz von 16 booleschen Variablen
Zeitdifferenz ohne Datum
Nhere Informationen zu den Datentypen 33, 35 und 54 finden Sie im Projektierungshandbuch.
48
-3
-4
0.001 0.0001
-5
-6
0.0000
1
0.000001
Typ
Int8
Int16
Int32
Uint8
Uint16
Uint32
VisStr
N2
V2
TimD
4. Programmieren
Alle Parameter fr den Frequenzumrichter sind zur einfachen Auffindung und Auswahl in verschiedenen Parametergruppen organisiert.
0-xx: Betrieb/Display (Parameter zum Einstellen der allgemeinen Grundfunktionen)
1-xx Motor/Last (enthlt alle last- und motorbezogenen Parameter)
2-xx Bremsfunktionen
3-xx Sollwert/Rampen (enthlt die DigitalPoti-Funktion)
4-xx Grenzen/Warnungen
5-xx Digit. Ein-/Ausgnge (inklusive Relaissteuerungen)
6-xx Analoge Ein-/Ausg.
7-xx PID-Regler (Einstellparameter fr Drehzahl- und Prozessregelungen)
8-xx Opt./Schnittstellen (Einstellung von FC RS485- und FC USB-Schnittstellenparametern)
9-xx Profibus DP
10-xx CAN/DeviceNet
13-xx Smart Logic
14-xx Sonderfunktionen
15-xx Info/Wartung
16-xx Datenanzeigen
17-xx Drehgeber Opt.
32-xx MCO-Grundeinstellungen (MCO 305)
33-xx MCO Erw. Einstell. (MCO 305)
34-xx MCO-Datenanzeigen
49
50
0-0* Grundeinstellungen
0-01
Sprache
0-02
Hz/UPM Umschaltung
0-03
Lndereinstellungen
0-04
Netz-Ein Modus (Hand)
0-1* Parameterstze
0-10
Aktiver Satz
0-11
Programm Satz
0-12
Satz verknpfen mit
0-13
Anzeige: Verknpfte Parameterstze
0-14
Anzeige: Par.stze/Kanal bearbeiten
0-2* LCP-Display
0-20
Displayzeile 1.1
0-21
Displayzeile 1.2
0-22
Displayzeile 1.3
0-23
Displayzeile 2
0-24
Displayzeile 3
0-25
Benutzer-Men
0-3* LCP-Benutzerdef
0-30
Einheit fr benutzerdefinierte Anzeige
0-31
Min. Wert benutzerdef. Anzeige
0-32
Max. Wert benutzerdef. Anzeige
0-4* LCP-Tasten
0-40
[Hand On]-LCP Taste
0-41
[Off]-LCP Taste
0-42
[Auto On]-LCP Taste
0-43
[Reset]-LCP Taste
0-5* Kopie/Speichern
0-50
LCP-Kopie
0-51
Parametersatz-Kopie
0-6* Passwort
0-60
Hauptmen Passwort
0-61
Hauptmen Zugriff ohne PW
0-65
Quick-Men Passwort
0-66
Quickmen Zugriff ohne PW
0-67
Bus Password Access
Parameterbeschreibung
All set-ups
All set-ups
1 set-up
1 set-up
1 set-up
1 set-up
All set-ups
[0] Keine Kopie

[0] Keine Kopie
100 N/A
[0] Vollstndig
200 N/A
[0] Vollstndig
0 N/A
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
[0] Ohne
0.00 CustomReadoutUnit
All
All
All
All
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
1617
1614
1610
1613
1602
SR
Aktiviert
Aktiviert
Aktiviert
Aktiviert
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
[1] Satz 1
[1] Satz 1
[0] Nicht verknpft
0 N/A
0 N/A
[1]
[1]
[1]
[1]
1 set-up
2 set-ups
2 set-ups
All set-ups
[0] English
[0] U/min [UPM]
[0] International
[1] LCP Stop,Letz.Soll.
Werkseinstellung
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
TRUE
TRUE
FALSE
FALSE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
4.3.1. 0-** Betrieb/Display
0
0
0
-2
-2
0
0
Konvertierungsindex
Int16
Uint8
Int16
Uint8
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Int32
Int32
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint8
Uint8
Uint8
Uint16
Int32
Uint8
Uint8
Uint8
Uint8
Typ
4. Programmieren
1-00
Regelverfahren
1-01
Steuerprinzip
1-02
Drehgeber Anschluss
1-03
Drehmomentverhalten der Last
1-04
berlastmodus
1-05
Hand/Ort-Betrieb Konfiguration
1-1* Motorauswahl
1-10
Motorart
1-2* Motordaten
1-20
Motornennleistung [kW]
1-21
Motornennleistung [PS]
1-22
Motornennspannung
1-23
Motornennfrequenz
1-24
Motornennstrom
1-25
Motornenndrehzahl
1-26
Dauer-Nenndrehmoment
1-29
Autom. Motoranpassung
1-3* Erw. Motordaten
1-30
Statorwiderstand (Rs)
1-31
Rotorwiderstand (Rr)
1-33
Statorstreureaktanz (X1)
1-34
Rotorstreureaktanz (X2)
1-35
Hauptreaktanz (Xh)
1-36
Eisenverlustwiderstand (Rfe)
1-37
Indukt. D-Achse (Ld)
1-39
Motorpolzahl
1-40
Gegen-EMK bei 1000 UPM
1-41
Geber-Offset
1-5* Lastunabh. Einst.
1-50
Motormagnetisierung bei 0 UPM.
1-51
Min. Drehzahl norm. Magnetis. [UPM]
1-52
Min. Drehzahl norm. Magnetis. [Hz]
1-53
Steuerprinzip Umschaltpunkt
1-55
U/f-Kennlinie - U [V]
1-56
U/f-Kennlinie - f [Hz]
Par.-Nr.
4.3.2. 1-** Motor/Last
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
SR
SR
SR
SR
SR
SR
SR
SR
SR
0 N/A
100 %
SR
SR
SR
SR
SR
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All
All
All
All
All
All
SR
SR
SR
SR
SR
SR
SR
[0] Anpassung aus
[0] Asynchron
null
null
[1] 24V/HTL-Drehgeber
[0] Konstant. Drehmom.
[0] Hohes bermoment
[2] Wie Par. 1-00
Werkseinstellung
nur
FC 302
Konvertierungsindex
1
-2
0
0
-2
67
-1
-4
-4
-4
-4
-4
-3
-4
0
0
0
0
67
-1
-1
-1
-1
ndern whrend
des Betriebs
TRUE
FALSE
FALSE
TRUE
FALSE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint32
Uint32
Uint32
Uint32
Uint32
Uint32
Int32
Uint8
Uint16
Int16
Uint32
Uint32
Uint16
Uint16
Uint32
Uint16
Uint32
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Typ

4. Programmieren
51
52
1-6* Lastabh. Einstellung

1-60
Lastausgleich tief
1-61
Lastausgleich hoch
1-62
Schlupfausgleich
1-63
Schlupfausgleich Zeitkonstante
1-64
Resonanzdmpfung
1-65
Resonanzdmpfung Zeitkonstante
1-66
Min. Strom bei niedr. Drz.
1-67
Lasttyp
1-68
Massentrgheit Min.
1-69
Massentrgheit Max.
1-7* Startfunktion
1-71
Startverzg.
1-72
Startfunktion
1-73
Motorfangschaltung
1-74
Startdrehzahl [UPM]
1-75
Startdrehzahl [Hz]
Startstrom
1-76
1-8* Stoppfunktion
1-80
Funktion bei Stopp
1-81
Ein.-Drehzahl fr Stoppfunktion [UPM]
1-82
Ein.-Frequenz fr Stoppfunktion [Hz]
1-83
Prziser Stopp-Funktion
1-84
Prziser Stopp-Wert
1-85
Verzgerung Drehzahlkompensation
1-9* Motortemperatur
1-90
1-91
Fremdbelftung
1-93
Thermistoranschluss
1-95
KTY-Sensortyp
1-96
KTY-Sensoranschluss
1-97
KTY-Schwellwert
All
All
All
All
All
All
All
All
All
All
All
All
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
0.0 s
[2] Freilauf/Verz.zeit
[0] Deaktiviert
SR
SR
0.00 A
[0] Motorfreilauf
SR
SR
[0] Prz. Rampenstopp
100000 N/A
10 ms
[0] Kein Motorschutz
[0] Nein
[0] Ohne
[0] KTY-Sensor 1
[0] Ohne
80 C
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
100 %
100 %
SR
SR
100 %
5 ms
100 %
[0] Passiv
SR
SR
Werkseinstellung
x
x
x
x
x
x
x
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
ndern whrend
des Betriebs
Par.-Nr.
100
67
-1
0
-3
-1
67
-1
-2
0
0
0
-2
0
-3
0
-4
-4
Konvertierungsindex
Uint8
Uint16
Uint8
Uint8
Uint8
Int16
Uint8
Uint16
Uint16
Uint8
Uint32
Uint8
Uint8
Uint8
Uint8
Uint16
Uint16
Uint32
Int16
Int16
Int16
Uint16
Uint16
Uint8
Uint8
Uint8
Uint32
Uint32
Typ
4. Programmieren
2-0* DC Halt/DC Bremse

2-00
DC-Haltestrom
2-01
DC-Bremsstrom
2-02
DC-Bremszeit
2-03
DC-Bremse Ein [UPM]
2-04
DC-Bremse Ein [Hz]
2-1* Generator. Bremsen
2-10
Bremsfunktion
2-11
Bremswiderstand (Ohm)
2-12
Bremswiderstand Leistung (kW)
2-13
Bremswiderst. Leistungsberwachung
2-15
Bremswiderstand Test
2-16
AC-Bremse max. Strom
2-17
berspannungssteuerung
2-2* Mech. Bremse
2-20
Bremse ffnen bei Motorstrom
2-21
Bremse schliessen bei Motordrehzahl
2-22
Bremse schlieen bei Motorfrequenz
2-23
Mech. Bremse Verzgerungszeit
2-24
Stop Delay
2-25
Brake Release Time
2-26
Torque Ref
2-27
Torque Ramp Time
2-28
Gain Boost Factor
Par.-Nr.
4.3.3. 2-** Bremsfunktionen
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
null
SR
SR
[0] Deaktiviert
[0] Deaktiviert
100.0 %
[0] Deaktiviert
ImaxVLT (P1637)
SR
SR
0.0 s
0.0 s
0.20 s
0.00 %
0.2 s
1.00 N/A
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
50 %
50 %
10.0 s
SR
SR
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
0
-1
67
-1
0
0
-1
-2
67
-1
-1
-1
-2
-2
-1
-2
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint32
Uint16
Uint16
Uint8
Uint8
Uint16
Int16
Uint8
Uint16
Uint8
Uint16
Uint32
Uint8
Uint8
Uint32
Uint8
Uint8
Uint16
Uint16
Uint16
Uint16
Typ
4. Programmieren
53
54
3-0* Sollwertgrenzen
3-00
Sollwertbereich
3-01
Soll-/Istwerteinheit
3-02
Minimaler Sollwert
3-03
Max. Sollwert
3-04
Sollwertfunktion
3-1* Sollwerteinstellung
3-10
Festsollwert
3-11
Festdrehzahl Jog [Hz]
3-12
Frequenzkorrektur Auf/Ab
3-13
Sollwertvorgabe
3-14
Relativer Festsollwert
3-15
Variabler Sollwert 1
3-16
3-17
3-18
Relativ. Skalierungssollw. Ressource
3-19
Festdrehzahl Jog [UPM]
3-4* Rampe 1
3-40
Rampentyp 1
3-41
Rampenzeit Auf 1
3-42
Rampenzeit Ab 1
3-45
SS-Form Anfang (Rampe Auf 1)
3-46
S-Form Ende (Rampe Auf 1)
3-47
S-Form Anfang (Rampe Ab 1)
3-48
S-Form Ende (Rampe Ab 1)
3-5* Rampe 2
3-50
Rampentyp 2
3-51
Rampenzeit Auf 2
3-52
Rampenzeit Ab 2
3-55
S-Form Anfang (Rampe Auf 2)
3-56
3-57
3-58
All
All
All
All
All
All
All
All
All
All
All
All
All
All
[0] Linear
SR
SR
50 %
50 %
50 %
50 %
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
0.00 %
SR
0.00 %
[0] Umschalt. Hand/Auto
0.00 %
null
null
null
[0] Deaktiviert
SR
[0] Linear
SR
SR
50 %
50 %
50 %
50 %
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
null
null
0 ReferenceFeedbackUnit
SR
[0] Addierend
Werkseinstellung
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
4.3.4. 3-** Sollwert/Rampen
-2
-2
0
0
0
0
-2
-2
0
0
0
0
-2
-1
-2
-2
67
-3
-3
-
Konvertierungsindex
Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8
Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8
Int16
Uint16
Int16
Uint8
Int32
Uint8
Uint8
Uint8
Uint8
Uint16
Uint8
Uint8
Int32
Int32
Uint8
Typ
4. Programmieren
3-6* Rampe 3
3-60
Rampentyp 3
3-61
Rampenzeit Auf 3
3-62
Rampenzeit Ab 3
3-65
3-66
3-67
3-68
3-7* Rampe 4
3-70
Rampentyp 4
3-71
Rampenzeit Auf 4
3-72
Rampenzeit Ab 4
3-75
3-76
3-77
3-78
3-8* Weitere Rampen
3-80
Rampenzeit JOG
3-81
Rampenzeit Schnellstopp
3-9* Digitalpoti
3-90
Digitalpoti Einzelschritt
3-91
Digitalpoti Rampenzeit
3-92
Digitalpoti speichern bei Netz-Aus
3-93
Digitalpoti Max. Grenze
3-94
Digitalpoti Min. Grenze
3-95
Rampenverzgerung
Par.-Nr.
0.10 %
1.00 s
[0] Aus
100 %
-100 %
1.000 N/A
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
2 set-ups
All
All
All
All
All
All
All
[0] Linear
SR
SR
50 %
50 %
50 %
50 %
SR
SR
All
All
All
All
All
All
All
[0] Linear
SR
SR
50 %
50 %
50 %
50 %
Werkseinstellung
nur
FC 302
Konvertierungsindex
-2
-2
0
0
0
0
-2
-2
0
0
0
0
-2
-2
-2
-2
0
0
-3
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint16
Uint32
Uint8
Int16
Int16
TimD
Uint32
Uint32
Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8
Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8
Typ

4. Programmieren
55
56
4-1* Motor Grenzen

4-10
Motor Drehrichtung
4-11
Min. Drehzahl [UPM]
4-12
Min. Frequenz [Hz]
4-13
Max. Drehzahl [UPM]
4-14
Max Frequenz [Hz]
4-16
Momentengrenze motorisch
4-17
Momentengrenze generatorisch
4-18
Stromgrenze
Max. Ausgangsfrequenz
4-19
4-2* Variable Grenzen
4-20
Variable Drehmomentgrenze
4-21
Variable Drehzahlgrenze
4-3* Drehg. berw.
4-30
Drehgeberberwachung Funktion
4-31
Drehgeber max. Fehlabweichung
4-32
Drehgeber Timeout-Zeit
4-5* Warnungen Grenzen
4-50
Warnung Strom niedrig
4-51
Warnung Strom hoch
4-52
Warnung Drehz. niedrig
4-53
Warnung Drehz. hoch
4-54
Warnung Sollwert niedr.
4-55
Warnung Sollwert hoch
4-56
Warnung Istwert niedr.
4-57
Warnung Istwert hoch
4-58
Motorphasen berwachung
4-6* Drehz.ausblendung
4-60
Ausbl. Drehzahl von [UPM]
4-61
Ausbl. Drehzahl von [Hz]
4-62
Ausbl. Drehzahl bis [UPM]
4-63
Ausbl. Drehzahl bis [Hz]
All
All
All
All
All
All
All
All
All
All
All
All
All
0.00 A
ImaxVLT (P1637)
0 RPM
outputSpeedHighLimit (P413)
-999999.999 N/A
999999.999 N/A
-999999.999 ReferenceFeedbackUnit
999999.999 ReferenceFeedbackUnit
[1] Ein
SR
SR
SR
SR
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
[2] Alarm
300 RPM
0.05 s
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All
All
All
All
All
All
All
All
All
[0] Ohne Funktion

[0] Ohne Funktion
null
SR
SR
SR
SR
SR
100.0 %
SR
132.0 Hz
Werkseinstellung
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
ndern whrend
des Betriebs
Par.-Nr.
4.3.5. 4-** Grenzen/Warnungen
67
-1
67
-1
-2
-2
67
67
-3
-3
-3
-3
-
67
-2
67
-1
67
-1
-1
-1
-1
-1
Konvertierungsindex
Uint16
Uint16
Uint16
Uint16
Uint32
Uint32
Uint16
Uint16
Int32
Int32
Int32
Int32
Uint8
Uint8
Uint16
Uint16
Uint8
Uint8
Uint8
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint32
Uint16
Typ
4. Programmieren
5-00
Schaltlogik
5-01
Klemme 27 Funktion
5-02
Klemme 29 Funktion
5-1* Digitaleingnge
5-10
Klemme 18 Digitaleingang
5-11
5-12
5-13
5-14
5-15
5-16
Klemme X30/2 Digitaleingang
5-17
5-18
5-19
Terminal 37 Safe Stop
5-20
Terminal X46/1 Digital Input
5-21
5-22
5-23
5-24
5-25
5-26
5-3* Digitalausgnge
5-30
Klemme 27 Digitalausgang
5-31
Klemme 29 Digitalausgang
5-32
Klemme X30/6 Digitalausgang
5-33
5-4* Relais
5-40
Relaisfunktion
5-41
Ein Verzg., Relais
5-42
Aus Verzg., Relais
5-5* Pulseingnge
5-50
Klemme 29 Min. Frequenz
5-51
Klemme 29 Max. Frequenz
5-52
Klemme 29 Min. Soll-/Istwert
5-53
Klemme 29 Max. Soll-/Istwert
5-54
Pulseingang 29 Filterzeit
5-55
Klemme 33 Min. Frequenz
5-56
Klemme 33 Max. Frequenz
5-57
Klemme 33 Min. Soll-/Istwert
5-58
Klemme 33 Max. Soll-/Istwert
5-59
Pulseingang 33 Filterzeit
Par.-Nr.
4.3.6. 5-** Digit. Ein-/Ausgnge
100 Hz
100 Hz
SR
100 ms
100 Hz
100 Hz
SR
100 ms
null
0.01 s
0.01 s
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
All
All
All
All
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
null
null
null
null
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[1] Safe Stop Alarm
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
null
null
null
null
All set-ups
All set-ups
All set-ups
[0] PNP
[0] Eingang
[0] Eingang
Werkseinstellung
x
x
x
x
x
nur
FC 302
Konvertierungsindex
-2
-2
0
0
-3
-3
-3
0
0
-3
-3
-3
ndern whrend
des Betriebs
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
FALSE
Uint32
Uint32
Int32
Int32
Uint16
Uint32
Uint32
Int32
Int32
Uint16
Uint8
Uint16
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Typ

4. Programmieren
57
58
5-6* Pulsausgnge
5-60
Klemme 27 Pulsausgang
5-62
Ausgang 27 Max. Frequenz
5-63
Klemme 29 Pulsausgang
5-65
Ausgang 29 Max. Frequenz
5-66
Klemme X30/6 Pulsausgang
5-68
Ausgang X30/6 Max. Frequenz
5-7* 24V Drehgeber
5-70
Kl. 32/33 Drehgeber Aufl. [Pulse/U]
5-71
Kl. 32/33 Drehgeber Richtung
5-9* Bussteuerung
5-90
Dig./Relais Ausg. Bussteuerung
5-93
Klemme 27, Wert bei Bussteuerung
5-94
Klemme 27, Wert bei Bus-Timeout
5-95
Klemme 29, Wert bei Bussteuerung
5-96
Klemme 29, Wert bei Bus-Timeout
All set-ups
All set-ups
1 set-up
All set-ups
1 set-up
0 N/A
0.00 %
0.00 %
0.00 %
0.00 %
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All
All
All
All
All
All
1024 N/A
[0] Rechtslauf
null
SR
null
SR
null
SR
Werkseinstellung
x
x
x
x
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
0
-2
-2
-2
-2
0
-
0
0
0
Konvertierungsindex
Uint32
N2
Uint16
N2
Uint16
Uint16
Uint8
Uint8
Uint32
Uint8
Uint32
Uint8
Uint32
Typ
4. Programmieren
6-00
Signalausfall Zeit
6-01
Signalausfall Funktion
6-1* Analogeingang 1
6-10
Klemme 53 Skal. Min.Spannung
6-11
Klemme 53 Skal. Max.Spannung
6-12
Klemme 53 Skal. Min.Strom
6-13
Klemme 53 Skal. Max.Strom
6-14
Klemme 53 Skal. Min.-Soll/Istwert
6-15
Klemme 53 Skal. Max.-Soll/Istwert
6-16
Klemme 53 Filterzeit
6-20
Klemme 54 Skal. Min.Spannung
6-21
Klemme 54 Skal. Max.Spannung
6-22
Klemme 54 Skal. Min.Strom
6-23
Klemme 54 Skal. Max.Strom
6-24
Klemme 54 Skal. Min.-Soll/Istwert
6-25
Klemme 54 Skal. Max.-Soll/Istwert
6-26
Klemme 54 Filterzeit
6-30
Kl.X30/11 Skal. Min. Spannung
6-31
Kl.X30/11 Skal. Max.Spannung
6-34
Kl.X30/11 Skal. Min.-Soll/Istw
6-35
Kl.X30/11 Skal. Max.-Soll/Istw
6-36
Klemme X30/11 Filterzeit
6-40
Klemme X30/12 Skal. Min.Spannung
6-41
Klemme X30/12 Skal. Max.Spannung
6-44
Kl.X30/12 Skal. Min.-Soll/Istw
6-45
Kl.X30/12 Skal. Max.-Soll/Istw
6-46
Klemme X30/12 Filterzeit
6-5* Analogausgang 1
6-50
Klemme 42 Analogausgang
6-51
Kl. 42, Ausgang min. Skalierung
6-52
Kl. 42, Ausgang max. Skalierung
6-53
Kl. 42, Wert bei Bussteuerung
6-54
Kl. 42, Wert bei Bus-Timeout
6-6* Analogausgang 2
6-60
Klemme X30/8 Analogausgang
6-61
Kl. X30/8, Ausgang min. Skalierung
6-62
Kl. X30/8, Ausgang max. Skalierung
6-7* Analog Output 3
6-70
Terminal X45/1 Output
6-71
Terminal X45/1 Min. Scale
6-72
Terminal X45/1 Max. Scale
6-8* Analog Output 4
6-80
Terminal X45/3 Output
6-81
Terminal X45/3 Min. Scale
6-82
Terminal X45/3 Max. Scale
Par.-Nr.
4.3.7. 6-** Analoge Ein-/Ausg.
All
All
All
All
All
All
All
All
All
All
0.07 V
10.00 V
SR
0.001 s
0.07 V
10.00 V
SR
0.001 s
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
null
0.00 %
100.00 %
0.00 %
0.00 %
null
0.00 %
100.00 %
null
0.00 %
100.00 %
null
0.00 %
100.00 %
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
0.07 V
10.00 V
0.14 mA
20.00 mA
SR
0.001 s
0.07 V
10.00 V
0.14 mA
20.00 mA
SR
0.001 s
All set-ups
All set-ups
10 s
[0] Aus
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
-2
-2
-5
-5
-3
-3
-3
-2
-2
-5
-5
-3
-3
-3
-2
-2
-3
-3
-3
-2
-2
-3
-3
-3
-2
-2
-2
-2
-2
-2
-2
-2
-2
-2
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint8
Int16
Int16
Uint8
Int16
Int16
Uint8
Int16
Int16
Uint8
Int16
Int16
N2
Uint16
Int16
Int16
Int32
Int32
Uint16
Int16
Int16
Int32
Int32
Uint16
Int16
Int16
Int16
Int16
Int32
Int32
Uint16
Int16
Int16
Int16
Int16
Int32
Int32
Uint16
Uint8
Uint8
Typ

4. Programmieren
59
60
7-0* PID Drehzahlregler

7-00
Drehgeberrckfhrung
7-02
Drehzahlregler P-Verstrkung
7-03
Drehzahlregler I-Zeit
7-04
Drehzahlregler D-Zeit
7-05
Drehzahlregler D-Verstrk./Grenze
7-06
Drehzahlregler Tiefpassfilterzeit
7-08
Drehzahlregler Vorsteuerung
7-2* PID-Prozess Istw.
7-20
PID-Prozess Istwert 1
7-22
PID-Prozess Istwert 2
7-3* PID-Prozessregler
7-30
Auswahl Normal-/Invers-Regelung
7-31
PID-Prozess Anti-Windup
7-32
PID-Prozess Reglerstart bei
7-33
PID-Prozess P-Verstrkung
7-34
PID-Prozess I-Zeit
7-35
PID-Prozess D-Zeit
7-36
PID-Prozess D-Verstrkung/Grenze
7-38
PID-Prozess Vorsteuerung
7-39
Bandbreite Ist=Sollwert
[0] Normal
[1] Ein
0 RPM
0.01 N/A
10000.00 s
0.00 s
5.0 N/A
0%
5%
[0] Keine Funktion

[0] Keine Funktion
null
SR
SR
SR
5.0 N/A
10.0 ms
0%
Werkseinstellung
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All
All
All
All
All
All
All
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
ndern whrend
des Betriebs
Par.-Nr.
4.3.8. 7-** PID-Regler
67
-2
-2
-2
-1
0
0
-3
-4
-4
-1
-4
0
Konvertierungsindex
Uint8
Uint8
Uint16
Uint16
Uint32
Uint16
Uint16
Uint16
Uint8
Uint8
Uint8
Uint8
Uint16
Uint32
Uint16
Uint16
Uint16
Uint16
Typ
4. Programmieren
8-01
Fhrungshoheit
8-02
Aktives Steuerwort
8-03
Steuerwort Timeout-Zeit
8-04
Steuerwort Timeout-Funktion
8-05
Steuerwort Timeout-Ende
8-06
Timeout Steuerwort quittieren
Diagnose Trigger
8-07
8-1* Steuerwort
8-10
Steuerwortprofil
8-13
Zustandswort Konfiguration
8-3* Ser. FC-Schnittst.
8-30
FC-Protokoll
8-31
Adresse
8-32
FC-Baudrate
8-35
FC-Antwortzeit Min.-Delay
8-36
FC-Antwortzeit Max.-Delay
8-37
FC Interchar. Max.-Delay
8-4* FC/MC-Protokoll
8-40
Telegrammtyp
8-5* Betr. Bus/Klemme
8-50
Motorfreilauf
8-51
Schnellstopp
8-52
DC Bremse
8-53
Start
8-54
Reversierung
8-55
Satzanwahl
8-56
Festsollwertanwahl
8-9* Bus-Festdrehzahl
8-90
Bus-Festdrehzahl 1
8-91
Bus-Festdrehzahl 2
Par.-Nr.
4.3.9. 8-** Opt./Schnittstellen
100 RPM
200 RPM
All set-ups
All set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All
Klemme
Klemme
Klemme
Klemme
Klemme
Klemme
Klemme
[3]
[3]
[3]
[3]
[3]
[3]
[3]
ODER
ODER
ODER
ODER
ODER
ODER
ODER
2 set-ups
[1] Standardtelegr. 1
Bus
Bus
Bus
Bus
Bus
Bus
Bus
1 set-up
1 set-up
1 set-up
All set-ups
1 set-up
1 set-up
All set-ups
All set-ups
[0] FC-Profil
[1] Standardprofil
[0] FC-Profil
1 N/A
[2] 9600 Baud
10 ms
5000 ms
25 ms
All set-ups
All set-ups
1 set-up
1 set-up
1 set-up
All set-ups
2 set-ups
[0] Klemme und Steuerw.

null
1.0 s
[0] Aus
[1] Par.satz fortsetzen
[0] Kein Reset
[0] Deaktiviert
Werkseinstellung
nur
FC 302
Konvertierungsindex
-1
0
-3
-3
-3
67
67
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint16
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint16
Uint16
Uint16
Uint8
Uint8
Uint8
Uint8
Uint32
Uint8
Uint8
Uint8
Uint8
Typ

4. Programmieren
61
62
Sollwert
Istwert
PCD-Konfiguration Schreiben
PCD-Konfiguration Lesen
Teilnehmeradresse
Telegrammtyp
Signal-Parameter
Parameter bearbeiten
Profibus Steuerung deaktivieren
Safe Address
Zhler: Fehler im Speicher
Speicher: Alarmworte
Speicher: Fehlercode
Zhler: Fehler Gesamt
Profibus-Warnwort
Aktive Baudrate
Bus-ID
Profilnummer
Steuerwort 1
Zustandswort 1
Datenwerte speichern
Freq.umr. Reset
Definierte Parameter (1)
Genderte Parameter (1)
Profibus Revision Counter
9-00
9-07
9-15
9-16
9-18
9-22
9-23
9-27
9-28
9-31
9-44
9-45
9-47
9-52
9-53
9-63
9-64
9-65
9-67
9-68
9-71
9-72
9-80
9-81
9-82
9-83
9-84
9-90
9-91
9-92
9-93
9-94
9-99
0 N/A
0 N/A
SR
SR
126 N/A
[108] PPO 8
0
[1] Aktiviert
[1] Bussteuerung aktiv.
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
[255] Baudrate unbekannt
0 N/A
0 N/A
0 N/A
0 N/A
[0] Aus
[0] Normal Betrieb
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
Werkseinstellung
All set-ups
All set-ups
2 set-ups
2 set-ups
1 set-up
1 set-up
All set-ups
2 set-ups
2 set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
1 set-up
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
All set-ups
nur
FC 302
ndern whrend
des Betriebs
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
Par.-Nr.
4.3.10. 9-** Profibus DP

Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Uint16
Uint16
Uint16
Uint16
Uint8
Uint8
Uint16
Uint16
Uint8
Uint16
Uint16
Uint16
Uint16
Uint16
V2
Uint8
Uint16
OctStr[2]
V2
V2
Uint8
Uint8
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Typ
4. Programmieren
10-00
Protokoll
10-01
Baudratenauswahl
10-02
MAC-ID Adresse
10-05
Zhler bertragungsfehler
10-06
Zhler Empfangsfehler
10-07
Zhler Bus-Off
10-1* DeviceNet
10-10
Prozessdatentyp
10-11
Prozessdaten Schreiben Konfiguration
10-12
Prozessdaten Lesen Konfiguration
10-13
Warnparameter
10-14
DeviceNet Sollwert
10-15
DeviceNet Steuerung
10-2* COS-Filter
10-20
COS-Filter 1
10-21
COS-Filter 2
10-22
COS-Filter 3
10-23
COS-Filter 4
10-3* Parameterzugriff
10-30
Array Index
10-31
Datenwerte speichern
10-32
DeviceNet Revision
10-33
EEPROM speichern
10-34
DeviceNet-Produktcode
DeviceNet F-Parameter
10-39
10-5* CANopen
10-50
Prozessdaten Konfiguration-Schreiben
10-51
Prozessdaten Konfiguration-Lesen
Par.-Nr.
4.3.11. 10-** CAN/DeviceNet
All
All
All
All
0
0
0
0
2 set-ups
All set-ups
All set-ups
1 set-up
1 set-up
All set-ups
2 set-ups
2 set-ups
0 N/A
[0] Aus
SR
[0] Aus
SR
0 N/A
SR
SR
set-ups
set-ups
set-ups
set-ups
All set-ups
2 set-ups
2 set-ups
All set-ups
2 set-ups
2 set-ups
null
SR
SR
0 N/A
[0] Aus
[0] Aus
N/A
N/A
N/A
N/A
2 set-ups
2 set-ups
2 set-ups
All set-ups
All set-ups
All set-ups
null
null
SR
0 N/A
0 N/A
0 N/A
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
-
ndern whrend
des Betriebs
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint16
Uint16
Uint8
Uint8
Uint16
Uint8
Uint16
Uint32
Uint16
Uint16
Uint16
Uint16
Uint8
Uint16
Uint16
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Typ

4. Programmieren
63
64
13-0* SL-Controller
13-00
Smart Logic Controller
13-01
SL-Controller Start
13-02
SL-Controller Stopp
13-03
SL-Parameter Initialisieren
13-1* Vergleicher
13-10
Vergleicher-Operand
13-11
Vergleicher-Funktion
13-12
Vergleicher-Wert
13-2* Timer
13-20
SL-Timer
13-4* Logikregeln
13-40
Logikregel Boolsch 1
13-41
Logikregel Verknpfung 1
13-42
13-43
Logikregel Verknpfung 2
13-44
13-5* SL-Programm
13-51
SL-Controller Ereignis
13-52
SL-Controller Aktion
2 set-ups
2 set-ups
2 set-ups
1 set-up
2
2
2
2
2
2 set-ups
2 set-ups
null
null
SR
SR
null
null
null
null
null
null
null
set-ups
set-ups
set-ups
set-ups
set-ups
2 set-ups
2 set-ups
2 set-ups
All set-ups
null
null
null
[0] Kein Reset
Werkseinstellung
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
4.3.12. 13-** Smart Logic
-3
-3
Konvertierungsindex
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
TimD
Uint8
Uint8
Int32
Uint8
Uint8
Uint8
Uint8
Typ
4. Programmieren
14-0* IGBT-Ansteuerung
14-00
Schaltmuster
14-01
Taktfrequenz
14-03
bermodulation
14-04
PWM-Jitter
14-1* Netzausfall
14-10
Netzausfall-Funktion
14-11
Netzausfall-Spannung
14-12
Netzphasen-Unsymmetrie
14-2* Reset/Initialisieren
14-20
Quittierfunktion
14-21
Autom. Quittieren Zeit
14-22
Betriebsart
14-23
Typencodeeinstellung
14-25
Drehmom.grenze Verzgerungszeit
14-26
WR-Fehler Abschaltverzgerung
14-28
Produktionseinstellungen
14-29
Servicecode
14-3* Stromgrenze
14-30
Regler P-Verstrkung
14-31
Regler I-Zeit
14-4* Energieoptimierung
14-40
Quadr.Mom. Anpassung
14-41
Minimale AEO-Magnetisierung
14-42
Minimale AEO-Frequenz
14-43
Motor Cos-Phi
14-5* Umgebung
14-50
EMV-Filter
14-52
Lftersteuerung
14-53
Lfterberwachung
14-55
Ausgangsfilter
14-56
Capacitance Output Filter
14-57
Inductance Output Filter
14-7* Compatibility
14-72
VLT Alarm Word
14-73
VLT Warning Word
14-74
VLT Ext. Status Word
14-8* Options
14-80
Option Supplied by External 24VDC
Par.-Nr.
4.3.13. 14-** Sonderfunktionen
All set-ups
All set-ups
All
All
All
All
100 %
0.020 s
66 %
40 %
10 Hz
SR
1 set-up
All set-ups
All set-ups
1 set-up
1 set-up
1 set-up
All set-ups
All set-ups
All set-ups
2 set-ups
[1] Ein
[0] Auto
[1] Warnung
[0] Kein Filter
2.0 uF
7.000 mH
0 N/A
0 N/A
0 N/A
[1] Ja
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
2 set-ups
All set-ups
All set-ups
All set-ups
All set-ups
[0] Manual reset

10 s
[0] Normal Betrieb
null
60 s
SR
[0] Normal Betrieb
0 N/A
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
All
All
All
All
[0] Deaktiviert
SR
[0] Alarm
[1] SFAVM
null
[1] Ein
[0] Aus
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
0
0
0
0
0
-3
0
0
0
-2
-7
-6
0
0
0
-
ndern whrend
des Betriebs
TRUE
TRUE
FALSE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
Uint8
Uint32
Uint32
Uint32
Uint8
Uint8
Uint8
Uint8
Uint16
Uint16
Uint8
Uint8
Uint8
Uint16
Uint16
Uint16
Uint8
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Int32
Uint8
Uint16
Uint8
Uint8
Uint8
Uint8
Uint8
Typ

4. Programmieren
65
66
15-0* Betriebsdaten
15-00
Betriebsstunden
15-01
Motorlaufstunden
15-02
Zhler-kWh
15-03
Anzahl Netz-Ein
15-04
Anzahl bertemperaturen
15-05
Anzahl berspannungen
15-06
Reset Zhler-kWh
15-07
Reset Motorlaufstundenzhler
15-1* Echtzeitkanal
15-10
Echtzeitkanal Quelle
15-11
Echtzeitkanal Abtastrate
15-12
Echtzeitkanal Triggerereignis
15-13
Echtzeitkanal Protokollart
15-14
Echtzeitkanal Werte vor Trigger
15-2* Protokollierung
15-20
Protokoll: Ereignis
15-21
Protokoll: Wert
15-22
Protokoll: Zeit
15-3* Fehlerspeicher
15-30
Fehlerspeicher: Fehlercode
15-31
Fehlerspeicher: Wert
15-32
Fehlerspeicher: Zeit
15-4* Typendaten
15-40
FC-Typ
15-41
Leistungsteil
15-42
Nennspannung
15-43
Softwareversion
15-44
Typencode (original)
15-45
Typencode (aktuell)
15-46
Typ Bestellnummer
15-47
Leistungsteil Bestellnummer
15-48
LCP-Version
15-49
Steuerkarte SW-Version
15-50
Leistungsteil SW-Version
15-51
Typ Seriennummer
15-53
Leistungsteil Seriennummer
All
All
All
All
All
All
All
All
All
All
All
All
All
0
0
0
0
0
0
0
0
0
0
0
0
0
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All set-ups
All set-ups
All set-ups
0 N/A
0 N/A
0s
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
All set-ups
All set-ups
All set-ups
0 N/A
0 N/A
0 ms
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
2 set-ups
2 set-ups
1 set-up
2 set-ups
2 set-ups
All
All
All
All
All
All
All
All
0
SR
[0] FALSCH
[0] Kontinuierlich
50 N/A
0h
0h
0 kWh
0 N/A
0 N/A
0 N/A
[0] Kein Reset
[0] Kein Reset
Werkseinstellung
nur
FC 302
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
4.3.14. 15-** Info/Wartung
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-3
-3
0
74
74
75
0
0
0
-
Konvertierungsindex
VisStr[6]
VisStr[20]
VisStr[20]
VisStr[5]
VisStr[40]
VisStr[40]
VisStr[8]
VisStr[8]
VisStr[20]
VisStr[20]
VisStr[20]
VisStr[10]
VisStr[19]
Uint8
Int16
Uint32
Uint8
Uint32
Uint32
Uint16
TimD
Uint8
Uint8
Uint8
Uint32
Uint32
Uint32
Uint32
Uint16
Uint16
Uint8
Uint8
Typ
4. Programmieren
15-6* Install. Optionen

15-60
Option installiert
15-61
SW-Version Option
15-62
Optionsbestellnr.
15-63
Optionsseriennr.
15-70
Option A
15-71
Option A - Softwareversion
15-72
Option B
15-73
Option B - Softwareversion
15-74
Option C0
15-75
Option C0 - Softwareversion
15-76
Option C1
15-77
Option C1 - Softwareversion
15-9* Parameterinfo
15-92
Definierte Parameter
15-93
Genderte Parameter
15-98
Drive Identification
15-99
Parameter-Metadaten
Par.-Nr.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Werkseinstellung
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
nur
FC 302
Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ndern whrend
des Betriebs
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
Uint16
Uint16
VisStr[40]
Uint16
VisStr[30]
VisStr[20]
VisStr[8]
VisStr[18]
VisStr[30]
VisStr[20]
VisStr[30]
VisStr[20]
VisStr[30]
VisStr[20]
VisStr[30]
VisStr[20]
Typ
4. Programmieren
67
68
16-0* Anzeigen-Allgemein
16-00
Steuerwort
16-01
Sollwert [Einheit]
16-02
Sollwert %
16-03
Zustandswort
16-05
Hauptistwert [%]
16-09
Benutzerdefinierte Anzeige
16-1* Anzeigen-Motor
16-10
Leistung [kW]
16-11
Leistung [PS]
16-12
Motorspannung
16-13
Frequenz
16-14
Motorstrom
16-15
Frequenz [%]
16-16
Drehmoment [Nm]
16-17
Drehzahl [UPM]
16-18
Therm. Motorschutz
16-19
KTY-Sensortemperatur
16-20
Rotor-Winkel
Drehmoment [%]
16-22
16-3* Anzeigen-FU
16-30
DC-Spannung
16-32
Bremsleistung/s
16-33
Bremsleist/2 min
16-34
Khlkrpertemp.
16-35
FC berlast
16-36
Nenn-WR-Strom
16-37
Max.-WR-Strom
16-38
SL Contr.Zustand
16-39
Steuerkartentemp.
16-40
Echtzeitkanalspeicher voll
16-5* Soll- & Istwerte
16-50
Externer Sollwert
16-51
Puls-Sollwert
16-52
Istwert [Einheit]
16-53
Digitalpoti Sollwert
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
0.00 kW
0.00 hp
0.0 V
0.0 Hz
0.00 A
0.00 %
0.0 Nm
0 RPM
0%
0 C
0 N/A
0%
0V
0.000 kW
0.000 kW
0 C
0%
SR
SR
0 N/A
0 C
[0] Nein
0.0 N/A
0.0 N/A
0.00 N/A
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
0 N/A
0.0 %
0 N/A
0.00 %
Werkseinstellung
nur
FC 302
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
ndern whrend
des Betriebs
Par.-Nr.
4.3.15. 16-** Datenanzeigen
-1
-1
-3
-2
0
0
0
100
0
-2
-2
0
100
-
1
-2
-1
-1
-2
-2
-1
67
0
100
0
0
0
-3
-1
0
-2
-2
Konvertierungsindex
Int16
Int16
Int32
Int16
Uint16
Uint32
Uint32
Uint8
Uint8
Uint32
Uint32
Uint8
Uint8
Uint8
Int32
Int32
Uint16
Uint16
Int32
N2
Int16
Int32
Uint8
Int16
Uint16
Int16
V2
Int32
Int16
V2
N2
Int32
Typ
4. Programmieren
16-6* Anzeig. Ein-/Ausg.

16-60
Digitaleingnge
16-61
AE 53 Modus
16-62
Analogeingang 53
16-63
AE 54 Modus
16-64
Analogeingang 54
16-65
Analogausgang 42
16-66
Digitalausgnge
16-67
Pulseing. 29 [Hz]
16-68
Pulseing. 33 [Hz]
16-69
Pulsausg. 27 [Hz]
16-70
Pulsausg. 29 [Hz]
16-71
Relaisausgnge
16-72
Zhler A
16-73
Zhler B
16-74
Prziser Stopp-Zhler
16-75
Analogeingang X30/11
16-76
Analogeingang X30/12
16-77
Analogausg. X30/8 [mA]
16-78
Analog Out X45/1 [mA]
16-79
Analog Out X45/3 [mA]
16-8* Anzeig. Schnittst.
16-80
Bus Steuerwort 1
16-82
Bus Sollwert 1
16-84
Feldbus-Komm. Status
16-85
FC Steuerwort 1
16-86
FC Sollwert 1
16-9* Bus Diagnose
16-90
Alarmwort
16-91
Alarmwort 2
16-92
Warnwort
16-93
Warnwort 2
16-94
Erw. Zustandswort
Par.-Nr.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0
0
0
0
0
0
0
0
0
0
0 N/A
[0] Strom
0.000 N/A
[0] Strom
0.000 N/A
0.000 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0 N/A
0.000 N/A
0.000 N/A
0.000 N/A
0.000 N/A
0.000 N/A
Werkseinstellung
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
nur
FC 302
Konvertierungsindex
0
-3
-3
-3
0
0
0
0
0
0
0
0
0
-3
-3
-3
-3
-3
0
0
0
0
0
0
0
0
0
0
ndern whrend
des Betriebs
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
Uint32
Uint32
Uint32
Uint32
Uint32
V2
N2
V2
V2
N2
Uint16
Uint8
Int32
Uint8
Int32
Int16
Int16
Int32
Int32
Int32
Int32
Int16
Int32
Int32
Uint32
Int32
Int32
Int16
Int16
Int16
Typ

4. Programmieren
69
70
17-1* Inkrementalgeber
17-10
Signaltyp
17-11
Inkremental Auflsung [Pulse/U]
17-2* Absolutwertgeber
17-20
Protokollauswahl
17-21
Absolut Auflsung [Positionen/U]
17-24
SSI-Datenlnge
17-25
Taktgeschwindigkeit
17-26
SSI-Datentyp
17-34
HIPERFACE-Baudrate
17-5* Resolver
17-50
Resolver Pole
17-51
Resolver Eingangsspannung
17-52
Resolver Eingangsfrequenz
17-53
bersetzungsverhltnis
17-59
Resolver aktivieren
17-6* berw./Anwend.
17-60
Positive Drehgeberrichtung
17-61
Drehgeber berwachung
1 set-up
1 set-up
1 set-up
1 set-up
All set-ups
All set-ups
All set-ups
2 N/A
7.0 V
10.0 kHz
0.5 N/A
[0] Deaktiviert
[0] Rechtslauf
[1] Warnung
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All set-ups
All set-ups
[0] Keine
SR
13 N/A
SR
[0] Gray-Code
[4] 9600
[1] TTL (5V, RS422)

1024 N/A
Werkseinstellung
nur
FC 302
FALSE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
ndern whrend
des Betriebs
Par.-Nr.
4.3.16. 17-** Opt./Drehgeber
0
-1
2
-1
-
0
0
3
-
Konvertierungsindex
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint32
Uint8
Uint16
Uint8
Uint8
Uint8
Uint16
Typ
4. Programmieren
32-0* Drehgeber 2
32-00
Inkrem. Signaltyp
32-01
Inkrementalauflsung
32-02
Absolutwertprotokoll
32-03
Absolutwertauflsung
32-05
Absolutwertgeber-Datenlnge
32-06
Absolutwertgeber-Taktfrequenz
32-07
Absolutwertgeber Takt
32-08
Absolutwertgeber-Kabellnge
32-09
Drehgeberberwachung
32-10
Drehrichtung
32-11
Nenner Benutzereinheit
32-12
Zhler Benutzereinheit
32-3* Drehgeber 1
32-30
Inkrem. Signaltyp
32-31
Inkrementalauflsung
32-32
Absolutwertprotokoll
32-33
Absolutwertauflsung
32-35
Absolutwertgeber-Datenlnge
32-36
Absolutwertgeber-Taktfrequenz
32-37
Absolutwertgeber Takt
32-38
Absolutwertgeber-Kabellnge
32-39
Drehgeberberwachung
Drehgeberterminierung
32-40
32-5* Feedback Source
32-50
Source Slave
Par.-Nr.
4.3.17. 32-** MCO Grundeinstell.
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
2 set-ups
2
2
2
2
2
2
2
2
2
2
[1] TTL (5V, RS422)

1024 N/A
[0] Keine
8192 N/A
25 N/A
262.000 kHz
[1] Ein
0m
[0] Aus
[1] Ein
[2] Encoder 2
2
2
2
2
2
2
2
2
2
2
2
2
[1] TTL (5V, RS422)

1024 N/A
[0] Keine
8192 N/A
25 N/A
262.000 kHz
[1] Ein
0m
[0] Aus
[1] Normal Betrieb
1 N/A
1 N/A
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
-
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint8
Uint8
Uint32
Uint8
Uint32
Uint8
Uint32
Uint8
Uint16
Uint8
Uint8
Uint8
Uint32
Uint8
Uint32
Uint8
Uint32
Uint8
Uint16
Uint8
Uint8
Uint32
Uint32
Typ

4. Programmieren
71
72
32-6* PID-Regler
32-60
P-Faktor
32-61
D-Faktor
32-62
I-Faktor
32-63
Grenzwert fr Integralsumme
32-64
PID-Bandbreite
32-65
Vorsteuerung fr Geschwindgkeit
32-66
Vorsteuerung der Beschleunigung
32-67
Max. tolerierter Positionsfehler
32-68
Reversierverhalten fr Slave
32-69
Abtastzeit fr PID-Regler
32-70
Abtastzeit fr Profilgeber
32-71
Gre des Regelfensters (Aktivierung)
32-72
Gre des Regelfensters (Deaktiv.)
32-8* Geschw. u. Beschl.
32-80
Max. Geschw. (Drehgeber)
32-81
Krzeste Rampe
32-82
Rampentyp
32-83
Geschwindigkeitsteiler
32-84
Standardgeschwindigkeit
32-85
Standardbeschleunigung
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1500 RPM
1.000 s
[0] Linear
100 N/A
50 N/A
50 N/A
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
30 N/A
0 N/A
0 N/A
1000 N/A
1000 N/A
0 N/A
0 N/A
20000 N/A
[0] Reversier. zulssig
1 ms
1 ms
0 N/A
0 N/A
Werkseinstellung
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
67
-3
0
0
0
0
0
0
0
0
0
0
0
-3
-3
0
0
Konvertierungsindex
Uint32
Uint32
Uint8
Uint32
Uint32
Uint32
Uint32
Uint32
Uint32
Uint16
Uint16
Uint32
Uint32
Uint32
Uint8
Uint16
Uint8
Uint32
Uint32
Typ
4. Programmieren
33-0* Ref.punktbeweg.
33-00
Referenzfahrt erzwingen
33-01
Nullpunktversatz von Ref.pkt.
33-02
Rampe fr Referenzfahrt
33-03
Geschw. der Ref.pkt-Bewegung
33-04
Verhalten bei Ref.pkt.-Bewegung
33-1* Synchronisierung
33-10
Synchronisierungsfaktor Master (M: S)
33-11
Synchronisierungsfaktor Slave (M: S)
33-12
Position-Offset fr Synchronisierung
33-13
Gen.fen. fr Pos.syn.
33-14
Relative Slavegeschw.-Grenze
33-15
Markierungszahl fr Master
33-16
Markeranzahl fr Slave
33-17
Mastermarkierungsdistanz
33-18
Slavemarkerdistanz
33-19
Mastermarkertyp
33-20
Slavemarkertyp
33-21
Toleranzfenster Mastermarker
33-22
Toleranzfenster Slavemarker
33-23
Startverh. f. Markersynchronisierung.
33-24
Markeranzahl fr Fehler
33-25
Markeranzahl fr READY
33-26
Geschw.-Filter
33-27
Offset-Filterzeit
33-28
Markerfilterkonfig.
33-29
Filterzeit fr Markerfilter
33-30
Max. Markierungskorrektur
33-31
Synchronisierungstyp
33-4* Grenzwertverarb.
33-40
Verhalten an Endbegren.
33-41
Neg. Software-Endbegren.
33-42
Pos. Software-Endbegren.
33-43
Neg. Software-Endbegren. aktiv
33-44
Pos. Software-Endbegren. aktiv
33-45
Zeit in Zielfenster
33-46
Zielfenster-Grenzwert
33-47
Gre des Zielfensters
Par.-Nr.
4.3.18. 33-** MCO Erw. Einstell.
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1 N/A
1 N/A
0 N/A
1000 N/A
0%
1 N/A
1 N/A
4096 N/A
4096 N/A
[0] Drehgeber Z positiv
[0] Drehgeber Z positiv
0 N/A
0 N/A
[0] Startfunktion 1
10 N/A
1 N/A
0 us
0 ms
[0] Marker-Filter 1
0 ms
0 N/A
[0] Standard
[0] Fehlerroutine aufr.
-500000 N/A
500000 N/A
[0] Deaktiviert
[0] Deaktiviert
0 ms
1 N/A
0 N/A
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
[0] Keine Zwangsrcks.

0 N/A
10 N/A
10 N/A
[0] Rckwrts und Index
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-6
-3
-3
0
0
0
-3
0
0
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
Uint8
Int32
Int32
Uint8
Uint8
Uint8
Uint16
Uint16
Int32
Int32
Int32
Int32
Uint8
Uint16
Uint16
Uint32
Uint32
Uint8
Uint8
Uint32
Uint32
Uint16
Uint16
Uint16
Int32
Uint32
Uint8
Int32
Uint32
Uint8
Uint8
Int32
Uint32
Int32
Uint8
Typ

4. Programmieren
73
74
33-5* E/A-Konfiguration
33-50
33-51
33-52
33-53
33-54
33-55
33-56
33-57
33-58
33-59
33-60
Klemme X59/1 und X59/2 Funktion
33-61
33-62
33-63
33-64
33-65
33-66
33-67
33-68
33-69
33-70
33-8* Globale Parameter
33-80
Aktive Programmnummer
33-81
Netz-Ein-Zustand
33-82
Zustandsberw. FC300
33-83
Verhalten nach Fehler
33-84
Verhalten nach Esc.
33-85
Ext. 24 VDC fr MCO
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
-1 N/A
[1] Motor ein
[1] Ein
[0] Motorfreilauf
[0] Kontroll. Stopp
[0] Nein
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
[0] Ohne Funktion

[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[1] Ausgang
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
[0] Ohne Funktion
Werkseinstellung
nur
FC 302
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
ndern whrend
des Betriebs
Par.-Nr.
0
-
Konvertierungsindex
Int8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Uint8
Typ
4. Programmieren
34-0* PCD-Par. schreiben

34-01
PCD 1 Schreiben an MCO
34-02
34-03
34-04
34-05
34-06
34-07
34-08
34-09
34-10
34-2* PCD-Par. lesen
34-21
PCD 1 Lesen von MCO
34-22
PCD 2 Lesen von MCO
34-23
PCD 3 Lesen von MCO
34-24
PCD 4 Lesen von MCO
34-25
PCD 5 Lesen von MCO
34-26
PCD 6 Lesen von MCO
34-27
PCD 7 Lesen von MCO
34-28
PCD 8 Lesen von MCO
34-29
PCD 9 Lesen von MCO
34-30
PCD 10 Lesen von MCO
34-4* Anzeig. Ein-/ Ausg.
34-40
Digitaleingnge
34-41
Digitalausgnge
34-5* Prozessdaten
34-50
Istposition
34-51
Sollposition
34-52
Masteristposition
34-53
Slave-Indexposition
34-54
Master-Indexposition
34-55
Kurvenposition
34-56
Schleppabstand
34-57
Synchronisierungsfehler
34-58
Istgeschwindigkeit
34-59
Master-Istgeschwindigkeit
34-60
Synchronisationsstatus
34-61
Achsenstatus
34-62
Programmstatus
34-7* Diagnose-Anzeigen
34-70
MCO Alarmwort 1
34-71
MCO Alarmwort 2
Par.-Nr.
4.3.19. 34-** MCO-Datenanzeigen

0 N/A
0 N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
All set-ups
All set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
All
All
All
All
All
All
All
All
All
All
All
All
All
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
set-ups
0
0
0
0
0
0
0
0
0
0
0
0
0
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All set-ups
All set-ups
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0 N/A
0 N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Werkseinstellung
nur
FC 302
Konvertierungsindex
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ndern whrend
des Betriebs
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
TRUE
FALSE
FALSE
Uint32
Uint32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Int32
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Uint16
Typ

4. Programmieren
75
76
Netzversorgung (L1, L2, L3):

Versorgungsspannung
200-240 V 10 %
Versorgungsspannung
FC 301: 380-480 V / FC 302: 380-500 V 10 %
Versorgungsspannung
FC 302: 525-690 V 10 %
Netzfrequenz
50/60 Hz
Max. Ungleichgewicht zwischen Netzphasen
3,0 % der Versorgungsnennspannung
Wirkleistungsfaktor ()
0,9 bei Nennlast
Verschiebungsleistungsfaktor (cos )
nahe Eins (> 0,98)
Schalten am Netzeingang L1, L2, L3 7,5 kW
max. 2 x/Min.
Schalten am Netzeingang L1, L2, L3 11-75 kW
max. 1 x/Min.
Schalten am Netzeingang L1, L2, L3 90 kW

Umgebung gem EN60664-1
max. 1 x/2 min.

berspannungskategorie III/Verschmutzungsgrad 2
Das Gert ist fr Netzversorgungen geeignet, die maximal 100,000 ARMS (symmetrisch) bei maximal je 240/500/600/690 V liefern knnen.
Motorausgang (U, V, W):
Ausgangsspannung
0 - 100 % der Versorgungsspannung
Ausgangsfrequenz (0,25-75 kW)
FC 301: 0,2 Hz - 1000 Hz / FC 302: 0 - 1000 Hz
Ausgangsfrequenz (90-560 kW)
0 - 800* Hz
Ausgangsfrequenz bei Fluxvektorbetrieb (nur FC 302)

Schalten am Ausgang
0 - 300 Hz
Unbegrenzt
Rampenzeiten
0,01 - 3600 s
Spannungs- und leistungsabhngig

Drehmomentkennlinie:
Anlaufmoment (konstantes Drehmoment)
maximal 160 % fr 60 s*
Anlaufmoment
maximal 180 % bis 0,5 s*
berlastmoment (konstantes Drehmoment)
Anlaufmoment (variables Drehmoment)
berlastungsstrom (variables Drehmoment)
maximal 110 % fr 60 s
*Prozentwert auf Nenndrehmoment bezogen.

Digitaleingnge:
Programmierbare Digitaleingnge
FC 301: 4 (5) / FC 302: 4 (6)

18, 19, 271), 294), 32, 33,
Klemmennummer
Logik
PNP oder NPN
Spannungsbereich
0 - 24 V DC
Spannungsniveau, logisch '0' PNP
< 5 V DC
> 10 V DC
Spannungsniveau, logisch '0' NPN2)
> 19 V DC
Spannungslevel, logisch '1' NPN2)
< 14 V DC
Max. Spannung am Eingang
28 V DC
Pulsfrequenzbereich
0 - 110 kHz
(Arbeitszyklus) Min. Pulsbreite
4,5 ms
Eingangswiderstand, Ri
ca. 4 k
77

Sicherer Stopp, Klemme 373) (Klemme 37 ist feste PNP-Logik):
Spannungsbereich
0 - 24 V DC
< 4 V DC
>20 V DC
Eingangsnennstrom bei 24 V
50 mA rms
Eingangsnennstrom bei 20 V
60 mA rms
Eingangskapazitt
400 nF
Alle Digitaleingnge sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
1) Klemmen 27 und 29 knnen auch als Ausgang programmiert werden.
Auer Eingang fr Sicheren Stopp, Klemme 37.
3) Klemme 37 ist nur beim FC 302 und beim FC 301 A1 mit Sicherem Stopp verfgbar. Sie kann nur als Eingang fr die Funktion Sicherer Stopp
verwendet werden. Klemme 37 ist geeignet fr Installationen bis Sicherheitskategorie 3 nach EN 954-1 (Stoppkategorie 0 EN 60204-1) gem EU-
Maschinenrichtlinie 98/37/EG. Klemme 37 und die Funktion Sicherer Stopp sind entsprechend EN 60204-1, EN 50178, EN 61800-2, EN 61800-3 und
EN 954-1 ausgelegt. Fr korrekten und sicheren Gebrauch der Funktion Sicherer Stopp folgen Sie den entsprechenden Informationen und Anweisungen
im Projektierungshandbuch.
4) nur FC 302
Analogeingnge:
Anzahl Analogeingnge
Klemmennummer
53, 54
Betriebsart
Spannung oder Strom
Betriebsartumschaltung
Einstellung fr Spannung
Spannungsbereich
Schalter S201 und Schalter S202

Schalter S201/Schalter S202 = AUS (U)
FC 301: 0 bis + 10 V DC/FC 302: -10 bis +10 V DC (skalierbar)
ca. 10 k
Max. Spannung
20 V
Einstellung fr Strom
Schalter S201/Schalter S202 = EIN (I)
Strombereich
0/4 bis 20 mA (skalierbar)
ca. 200
Max. Strom
30 mA
Auflsung der Analogeingnge
10 Bit (+ Vorzeichen)
Genauigkeit der Analogeingnge
Max. Fehler 0,5 % der Gesamtskala
Bandbreite
FC 301: 20 Hz/FC 302: 100 Hz
Die Analogeingnge sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
78
Puls-/Drehgebereingnge:
Programmierbare Puls-/Drehgebereingnge
2/1
291), 332) / 323), 333)
Klemmennummer Puls/Drehgeber
Max. Frequenz bei Klemme 29, 32, 33
110 kHz (Gegentakt)
Max. Frequenz bei Klemme 29, 32, 33
5 kHz (offener Kollektor)
Min. Frequenz bei Klemme 29, 32, 33
4 Hz
Spannungsbereich
siehe Digitaleingnge
Max. Spannung am Eingang
28 V DC
ca. 4 k
Pulseingangsgenauigkeit (0,1-1 kHz)
Max. Fehler: 0,1 % der Gesamtskala
Drehgebereingangsgenauigkeit (1-110 kHz)
Die Puls- und Drehgebereingnge (Klemmen 29, 32, 33) sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen
isoliert.
1) Nur FC 302
2) Pulseingnge sind 29 und 33
3) Drehgebereingnge: 32 = A und 33 = B
Digitalausgang:
Programmierbare Digital-/Pulsausgnge
Klemmennummer
27, 29
1)
Spannungsbereich am Digital-/Frequenzausgang
0 - 24 V
Max. Ausgangsstrom (Krper oder Quelle)
40 mA
Max. Last am Pulsausgang
1 k
Max. kapazitive Last am Frequenzausgang
10 nF
Min. Ausgangsfrequenz am Pulsausgang
0 Hz
Max. Ausgangsfrequenz am Pulsausgang
32 kHz
Genauigkeit am Pulsausgang
Auflsung an Pulsausgngen
12 Bit
1) Klemmen 27 und 29 knnen auch als Digitaleingang programmiert werden.

Die Digitalausgnge sind galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
Analogausgnge:
Anzahl programmierbarer Analogausgnge
Klemmennummer
42
Strombereich am Analogausgang
0/4 - 20 mA
Max. Last gegen Masse am Analogausgang

Genauigkeit am Analogausgang
500
Auflsung am Analogausgang
12 Bit
Der Analogausgang ist galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
Steuerkarte, 24 V DC-Ausgang:
Klemmennummer
12, 13
Ausgangsspannung
24 V +1, -3 V
Max. Last
FC 301: 130 mA/FC 302: 200 mA
Die 24 V DC-Versorgung ist von der Versorgungsspannung (PELV) getrennt, hat aber das gleiche Potenzial wie die analogen und digitalen Ein- und
Ausgnge.
Steuerkarte, 10 V DC-Ausgang:
Klemmennummer
50
Ausgangsspannung
10,5 V 0,5 V
Max. Last
15 mA
Die 10 V DC-Versorgung ist galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
79

Steuerkarte, RS 485 serielle Schnittstelle:
Klemmennummer
68 (P,TX+, RX+), 69 (N,TX-, RX-)
Klemmennummer 61
Masse fr Klemmen 68 und 69
Die serielle RS 485-Schnittstelle ist von anderen zentralen Stromkreisen funktional und von der Versorgungsspannung (PELV) galvanisch getrennt.
Steuerkarte, USB (serielle Schnittstelle):

USB-Standard
1.1 (Full Speed)
USB-Stecker
USB-Stecker Typ B
Der Anschluss an einen PC erfolgt ber ein USB-Standardkabel.

Die USB-Verbindung ist galvanisch von der Versorgungsspannung (PELV) und anderen Hochspannungsklemmen getrennt.
Die USB-Verbindung ist nicht galvanisch von Schutzerde (PE) getrennt. Benutzen Sie nur einen isolierten Laptop als PC-Verbindung zum USB-Anschluss
am Frequenzumrichter.
Relaisausgnge:
Programmierbare Relaisausgnge
FC 301 7,5 kW: 1/FC 302 alle kW: 2
Klemmennummer Relais 01
1-3 (ffnen), 1-2 (schlieen)
Max. Klemmenleistung (AC-1)1) an 1-3 (ffnen), 1-2 (schlieen) (ohmsche Last)
240 V AC, 2 A
Max. Klemmenleistung (AC-15)1) (induktive Last @ cos 0,4)
240 V AC, 0,2 A
Max. Klemmenleistung (DC-1)1) an 1-2 (schlieen), 1-3 (ffnen) (ohmsche Last)
60 V DC, 1 A
Max. Klemmenleistung (DC-13)1) (induktive Last)
24 V DC, 0,1A
Klemmennummer Relais 02 (nur FC 302)

Max. Klemmenleistung
(AC-1)1)
4-6 (ffnen), 4-5 (schlieen)
an 4-5 (schlieen) (ohmsche
Last)2)3)
400 V AC, 2 A
Max. Klemmenleistung (AC-15)1) an 4-5 (schlieen) (induktive Last @ cos 0,4)
240 V AC, 0,2 A
Max. Klemmenleistung (DC-1)1) an 4-5 (schlieen) (ohmsche Last)
80 V DC, 2 A
Max. Klemmenleistung (DC-13)1) an 4-5 (schlieen) (induktive Last)
24 V DC, 0,1A
Max. Klemmenleistung (AC-1)1) an 4-6 (ffnen) (ohmsche Last)
240 V AC, 2 A
Max. Klemmenleistung (AC-15)1) an 4-6 (ffnen) (induktive Last @ cos 0,4)
240 V AC, 0,2 A
Max. Klemmenleistung (DC-1)1) an 4-6 ffnen) (ohmsche Last)

Max. Klemmenleistung
(DC-13)1)
50 V DC, 2 A
an 4-6 (ffnen) (induktive Last)
24 V DC, 0,1 A
Min. Klemmenleistung an 1-3 (ffnen), 1-2 (schlieen), 4-6 (ffnen) 4-5 (schlieen)
Umgebung nach EN 60664-1
24 V DC 10 mA, 24 V AC 20 mA
berspannungskategorie III/Verschmutzungsgrad 2
1) IEC 60947 Teil 4 und 5

Die Relaiskontakte sind galvanisch durch verstrkte Isolierung (PELV) vom Rest der Stromkreise getrennt.
2) berspannungskategorie II
3) UL-Anwendungen 300 V AC, 2 A
Kabellngen und -querschnitte fr Steuerkabel:
Max. Motorkabellnge, abgeschirmtes Kabel
FC 301: 50 m/FC 301 (A1-Gehuse): 25 m/FC 302: 150 m
Max. Motorkabellnge, nicht abgeschirmtes Kabel
FC 301: 75 m/FC 301 (A1-Gehuse): 50 m/FC 302: 300 m
Maximaler Querschnitt fr Steuerkabel, flexibler/starrer Draht ohne Aderendhlsen.

Maximaler Querschnitt fr Steuerkabel, flexibler Draht ohne Aderendhlsen.
Maximaler Querschnitt fr Steuerkabel, flexibler Draht mit Aderendhlsen und mit Bund.
1 mm2/18 AWG
0,5 mm2/20 AWG
0,25 mm2/ 24 AWG
Minimaler Querschnitt fr Steuerklemmen
* Weitere Informationen zu Stromkabeln finden Sie im Abschnitt Elektrische Daten des Projektierungshandbuchs.
Nhere Informationen siehe Abschnitt Elektrische Daten im FC 300-Projektierungshandbuch MG.33.BX.YY.
80
1,5 mm2/16 AWG
Steuerkartenleistung:
Abfragezeit
FC 301: 5 ms/FC 302: 1 ms
Steuerungseigenschaften:
Auflsung von Ausgangsfrequenz bei 0-1000 Hz
+/- 0,003 Hz
Wiederholgenauigkeit fr Prziser Start/Stopp (Klemmen 18, 19)
0,1 ms
System-Reaktionszeit (Klemmen 18, 19, 27, 29, 32, 33)
2 ms
Drehzahlregelbereich (ohne Rckfhrung)
1:100 der Synchrondrehzahl
Drehzahlsteuerbereich (mit Rckfhrung)
1:1000 der Synchrondrehzahl
Drehzahlgenauigkeit (ohne Rckfhrung)
30-4000 UPM, Fehler: 8 UPM
Drehzahlgenauigkeit (mit Rckfhrung), je nach Auflsung
0-6000 UPM, Fehler: 0,15 UPM
Alle Angaben basieren auf einem vierpoligen Asynchronmotor.
Umgebung:
IP 201)/Typ 1, IP 212)/Typ 1, IP 55/Typ 12, IP 66
Gehuse
Vibrationstest
1,0 g
Max. relative Luftfeuchtigkeit
5 % - 95 % (IEC 721-3-3; Klasse 3K3 (nicht kondensierend) bei Betrieb

Klasse H25
Aggressive Umgebung (IEC 60068-2-43

Umgebungstemperatur3)
Max. 50 C (24-Std.-Durchschnitt max. 45 C)
1) Nur fr 3,7 kW (200-240 V), 7,5 kW (400-480/500 V)

2) Als Gehuse-Kit fr 3,7 kW (200-240 V), 7,5 kW (400-480/500 V)
3) Angaben zur Leistungsreduzierung wegen hoher Umgebungstemperatur finden Sie unter Besondere Bedingungen im Projektierungshandbuch
Minimale Umgebungstemperatur bei Volllast
0 C
Minimale Umgebungstemperatur bei reduzierter Leistung
- 10 C
Temperatur bei Lagerung/Transport
-25 - +65/70 C
Maximale Hhe ber Meeresspiegel ohne Leistungsreduzierung
1000 m
Leistungsreduzierung bei niedrigem Luftdruck/groer Hhe; siehe Besondere Bedingungen im Projektierungshandbuch.

EMV-Normen, Straussendung
EN 61800-3, EN 61000-6-3/4, EN 55011

EN 61800-3, EN 61000-6-1/2,
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6
EMV-Normen, Strfestigkeit
Siehe Abschnitt zu besonderen Bedingungen im Projektierungshandbuch

Schutz und Merkmale:
Elektronisch thermischer Motor-berlastschutz.

Temperaturberwachung des Khlkrpers stellt sicher, dass der Frequenzumrichter abgeschaltet wird, wenn die Temperatur einen festgelegten
Wert erreicht. Eine berlasttemperatur kann erst zurckgesetzt werden, nachdem die Khlkrpertemperatur wieder unter die in den folgenden
Tabellen festgelegten Werte gesunken ist (dies ist nur eine Richtlinie: Temperaturen knnen je nach Leistungsgre, Gehuse usw. verschieden
sein).
Der Frequenzumrichter ist gegen Kurzschlsse an den Motorklemmen U, V, W geschtzt.
Bei fehlender Netzphase schaltet der Frequenzumrichter ab oder gibt eine Warnung aus (je nach Last).
Die berwachung der Zwischenkreisspannung gewhrleistet, dass der Frequenzumrichter abschaltet, wenn die Zwischenkreisspannung zu niedrig bzw. zu hoch ist.
Es erfolgt eine permanente berwachung hinsichtlich kritischer Werte bei interner Temperatur, Laststrom, Spannung im Zwischenkreis und
Motordrehzahl. Wenn ein kritisches Niveau erreicht wird, kann die Taktfrequenz angepasst und/oder der Schaltmodus gendert werden, damit
der Frequenzumrichter weiter betrieben werden kann.
81
82

6.1.1. Warnungen/Alarmmeldungen
Eine Warnung oder ein Alarm wird durch die entsprechende LED auf der Frontseite des Frequenzumrichters signalisiert und mit einem Code im Display
angezeigt.
Eine Warnung bleibt so lange bestehen, bis die Ursache nicht mehr zutrifft. Der Motor kann dabei eventuell weiter betrieben werden. Warnmeldungen
knnen, mssen aber nicht unbedingt kritisch sein.
Bei einem Alarm hat der Frequenzumrichter abgeschaltet. Alarme mssen zur Wiederaufnahme des Betriebs durch Beseitigung der Ursache quittiert
werden.
Dies kann auf drei Arten geschehen:
1.
Mit der Bedientaste [RESET] an der LCP-Bedieneinheit.
2.
ber einen Digitaleingang mit der Funktion Reset.
3.
ber serielle Kommunikation/optionalen Feldbus.
ACHTUNG!
Nach manuellem Quittieren ber die [RESET]-Taste am LCP muss die Taste [AUTO ON] gedrckt werden, um den Motor neu zu starten!
Wenn sich ein Alarm nicht quittieren lsst, kann dies daran liegen, dass die Ursache noch nicht beseitigt ist oder der Alarm mit einer Abschaltblockierung
versehen ist (siehe auch Tabelle auf der nchsten Seite).
Alarme mit Abschaltblockierung bieten einen zustzlichen Schutz, d. h., es muss vor der Quittierung die Netzversorgung abgeschaltet werden. Nach dem
Wiederzuschalten ist der Frequenzumrichter nicht mehr blockiert und kann nach Beseitigung der Ursache wie oben beschrieben quittiert werden.
Alarme ohne Abschaltblockierung knnen auch mittels der automatischen Quittierfunktion in Parameter 14-20 zurckgesetzt werden (Achtung: automatischer Wiederanlauf ist mglich!).
Ist in der Tabelle auf der folgenden Seite fr einen Code Warnung und Alarm markiert, bedeutet dies, dass entweder vor einem Alarm eine Warnung
erfolgt oder dass Sie festlegen knnen, ob fr einen bestimmten Fehler eine Warnung oder ein Alarm ausgegeben wird.
Dies ist beispielsweise in Parameter 1-90 Thermischer Motorschutz mglich. Nach einem Alarm/einer Abschaltung bleibt der Motor im Freilauf, und Alarm
und Warnung blinken. Nachdem das Problem behoben wurde, blinkt nur noch der Alarm.
83
No. Beschreibung
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
23
24
25
26
27
28
29
30
31
32
33
34
36
38
40
41
42
42
47
48
49
50
51
52
53
54
55
56
57
58
59
10 Volt niedrig
Signalfehler
Kein Motor
Netzunsymmetrie
DC-Spannung hoch
DC-Spannung niedrig
DC-berspannung
DC-Unterspannung
WR-berlast
Motortemperatur ETR
Motor Thermistor
Drehmomentgrenze
berstrom
Erdschluss
Inkompatible Hardware
Kurzschluss
Steuerwort-Timeout
Interne Lfter
Externe Lfter
Bremswiderstand Kurzschluss
Bremswiderstand Leistungsgrenze
Bremse IGBT-Fehler
Bremstest
Umrichter bertemperatur
Motorphase U fehlt
Motorphase V fehlt
Motorphase W fehlt
Inrush Fehler
Feldbus-Fehler
Netzausfall
Interner Fehler
Digitalausgang 27 ist berlastet
Digitalausgang 29 ist berlastet
Digitalausgang X30/6 ist berlastet
Digitalausgang X30/7 ist berlastet
24-V-Versorgung - Fehler
1,8-V-Versorgung - Fehler
Drehzahlgrenze
AMA-Kalibrierungsfehler
AMA-Motordaten Unom und Inom berprfen
AMA-Strom Inom
AMA-Motor zu gro
AMA-Motor zu klein
AMA-Daten auerhalb des Bereichs
AMA-Abbruch
AMA-Timeout
AMA - Interner Fehler
Stromgrenze
Warnung
X
(X)
(X)
(X)
X
X
X
X
X
(X)
(X)
X
X
X
(X)
X
X
X
(X)
X
(X)
X
(X)
(X)
(X)
X
X
(X)
(X)
(X)
(X)
X
X
X
X
Alarm/Abschaltung
Alarm/Abschaltblockierung
Parameter
Sollwert
(X)
6-01
1-80
14-12
(X)
(X)
X
X
X
(X)
(X)
X
X
X
X
X
(X)
1-90
1-90
X
X
X
X
8-04
14-53
(X)
X
(X)
X
(X)
(X)
(X)
X
X
X
X
X
X
2-13
X
(X)
(X)
(X)
X
4-58
4-58
4-58
X
X
X
X
X
X
X
X
X
X
X
Tabelle 6.1: Alarm-/Warncodeliste
84
2-15
5-00, 5-01
5-00, 5-02
5-32
5-33
No.
Beschreibung
61
62
Drehgeber-Fehler
Ausgangsfrequenz-Grenze
63
64
Mechanische Bremse - Fehler

Motorspannung
65
66
67
68
70
71
72
80
90
91
100199
250
251
Steuerkarte bertemperatur
Temperatur zu niedrig
Optionen neu
Sich. Stopp
Ungltige FC-Konfiguration
PTC 1 Sicherer Stopp
Gefhrlicher Fehler
Initialisiert
Drehgeberberwachung
Falsche Einstellungen fr Analogeingang 54
Warnung
(X)
X
Alarm/Abschaltung Alarm/Abschaltblockierung
(X)
(X)
Parameter
Sollwert
4-30
2-20
X
X
X
(X)
X
(X)1)
5-19
X
(X)
X1)
5-19
5-19
17-61
S202
X1)
X
(X)
Siehe Produkthandbuch zur MCO 305

Neues Ersatzteil
Neuer Typencode
X
X
14-23
Tabelle 6.2: Alarm-/Warncodeliste

(X) Parameterabhngig
1) Kann nicht automatisch ber Par. 14-20 quittiert werden
Bei einem Alarm folgt eine Abschaltung. Die Abschaltung fhrt zum Motorfreilauf und kann durch Drcken der Reset-Taste oder durch einen
Reset ber Digitaleingang (Par. 5-1* [1]) quittiert werden. Das ursprngliche Ereignis, das den Alarm hervorgerufen hat, kann den Frequenzumrichter nicht beschdigen oder gefhrliche Bedingungen schaffen. Bei
einem Alarm tritt die Abschaltblockierung in Kraft, die ggf. den Frequenzumrichter oder angeschlossene Teile beschdigen kann. Eine Abschaltblockierung kann nur durch Aus- und Einschalten des Frequenzumrichters
quittiert werden.
LED-Anzeige
Warnung
Alarm
Abschaltung blockiert
gelb
Blinkt ROT
gelb und rot
85
Alarmwort, erweitertes Zustandswort

Bit
Hex
Dez
Alarmwort
00000001
Bremstest
00000002
Umr. bertemp.
00000004
Erdschluss
00000008
Steuer.Temp.
00000010
16
STW- Timeout
5
6
7
8
00000020
00000040
00000080
00000100
32
64
128
256
berstrom
Moment.grenze
Motor Therm.
Motortemp.ETR
9
10
11
12
13
14
00000200
00000400
00000800
00001000
00002000
00004000
512
1024
2048
4096
8192
16384
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
00008000
00010000
00020000
00040000
00080000
00100000
00200000
00400000
00800000
01000000
02000000
04000000
08000000
10000000
20000000
40000000
32768
65536
131072
262144
524288
1048576
2097152
4194304
8388608
16777216
33554432
67108864
134217728
268435456
536870912
1073741824
31
80000000
2147483648
WR-berlast
DC-Untersp.
DC-bersp.
Kurzschluss
Inrush Fehler
Netzunsymm. Verlust
AMA nicht OK
Signalfehler
Interner Fehler
Bremswid.kW
Mot.Phase U
Mot.Phase V
Mot.Phase W
Feldbus-Fehl.
24 V Fehler
Netzausfall
1,8 V Fehler
Bremswiderst.
Bremse IGBT
Optionen neu
Initialisiert
Sicherer
Stopp
(A68)
Mech. Bremse
Alarmwort 2
Warnwort
Serviceabschaltung,
Lesen/
Schreiben
Serviceabschaltung, (reserviert)
Serviceabschaltung, Typencode/
Ersatzteil
Bremstest
Warnwort Erweitertes Men

2
Zustandswort
Rampe
Umr. bertemp.
AMA luft
Erdschluss
Start
lauf
Steuer.Temp.
Freq.korr. Ab
STW- Timeout
Freq.korr. Auf
berstrom
Moment.grenze
Motor Therm.
Motortemp.ETR
Istwert hoch
Istwert niedr.
Ausgangsstrom hoch
Ausgangsstrom niedrig
Ausgangsfreq. hoch
Ausgangsfreq. niedr.
Bremstest i.O.
Max. Bremsung
Bremsung
Auerh.Frequenzber.
WR-berlast
DC-Untersp.
DC-bersp.
DC-niedrig
DC-hoch
Netzunsymm. Verlust
Kein Motor
Signalfehler
KTY-Fehler
10 V niedrig
Lfterfehler
Bremswid.kW
ECB-Fehler
Bremswiderst.
Bremse IGBT
Drehz.grenze
Feldbus-Fehl.
24 V Fehler
Netzausfall
Stromgrenze
Temp. niedrig
Motorspannung
Drehgeber-Fehler
Ausg.Frequenz
PTC 1 Sicherer Sicherer Stopp (W68)
Stopp (A71)
Rechts-/Links-
bersp.-Steu.
AC Bremse
KTY-Warn. Passwort-Zeitblockier.
Lfterwarn. Passwort-Schutz
ECB-Warn.
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
Reserviert
PTC 1 Siche- Reserviert
rer
Stopp
(W71)
Gefhrlicher Fehler Erweitertes Zustandswort
Reserviert
(A72)
Tabelle 6.3: Beschreibung des Alarmworts, Warnworts und erweiterten Zustandsworts

Die Alarmworte, Warnworte und erweiterten Zustandsworte knnen ber den seriellen Bus oder optional ber den Feldbus zur Diagnose ausgelesen
werden. Sie auch Par. 16-90 - 16-94.
WARNUNG 1, 10 Volt niedrig:
oder ein Defekt im Gleichrichter.
Die 10-Volt-Spannung von Klemme 50 an der Steuerkarte ist unter 10
Siehe auch Par.14-12 Rcksetzen des Alarms nur nach Netz-AUS.
Volt.
WARNUNG 5, DC-Spannung hoch:
Die 10-Volt-Versorgung ist berlastet. Verringern Sie die Last an Klemme
Die Zwischenkreisspannung (VDC) liegt oberhalb der berspannungs-
50. Max. 15 mA bzw. minimal 590 Last.
grenze des Steuersystems. Eventuell wird die Steuerung ber externe 24
WARNUNG/ALARM 2, Sollwertfehler:
V versorgt. berprfen Sie die Netzspannung.
Das Analogsignal an Klemme 53/54 ist kleiner als 50 % der zugehrigen

Skalier.Min (Par.6-1*/6-2*), und eine Signalausfall-Funktion wurde in
Par. 6-01 aktiviert. berprfen Sie die Analogsignale an Klemme 53/54.
berprfen Sie die Einstellung in Par. 6-01.
spannungsgrenze erreicht. Eventuell wird die Steuerung ber externe 24
WARNUNG/ALARM 7, DC-berspannung:
In Par. 1-80 wurde als Stoppfunktion Motortest gewhlt, und es kann

am Umrichterausgang kein Motor gemessen werden. berprfen Sie die
Motorklemmen und die Einstellung in Par. 1-80.
Der Umrichter hat aufgrund einer berspannung im Zwischenkreis abgeschaltet.

berprfen Sie Netzspannung,
WARNUNG/ALARM 4, Netzunsymmetrie:
evtl. den Bremswiderstand (Option),
Es wurde zu hohes Ungleichgewicht in der Netzversorgung erkannt. Mgliche Ursachen: Eine fehlende Netzphase, zu hohe Unsymmetrie in der
86
Die Spannung (DC) im Umrichter-Zwischenkreis hat die interne UnterV versorgt. berprfen Sie die Netzspannung.
WARNUNG/ ALARM 3, Kein Motor:
Netzspannung
WARNUNG 6, DC-Spannung niedrig
Rampenzeiten (Par. 3-**),

Bremsfunktionen (Par. 2-10)

ALARM 15, Inkompatible Hardware:
und Motor/Last.
Eine installierte Option wird von der Steuerkartenfirmware nicht unterAlarm-/Warngrenzen:

3 x 200 - 240 3 x 380 - 500 3 x 525 - 600 V
V
V
[VDC]
[VDC]
[VDC]
Unterspannung
185
373
532
Unterer Spannungs205
410
585
grenzwert
Oberer Spannungs390/405
810/840
943/965
grenzwert (ohne/
mit Bremse)
berspannung
410
855
975
sttzt. Bitte wenden Sie sich an den Danfoss-Service.
Die angegebenen Spannungen sind die Zwischenkreisspannung des

Frequenzumrichters mit einer Toleranz von 5 %. Die entsprechende Netzspannung ist die Zwischenkreisspannung (Gleichstrom)
geteilt durch 1,35.
ist.
WARNUNG/ALARM 8, DC-Unterspannung:
Wenn die Zwischenkreisspannung (VDC) unter den unteren Spannungs-
ALARM 16, Kurzschluss:

Es wurde ein Kurzschluss an den Ausgangsphasen festgestellt.
berprfen Sie die Isolation des Motors und des Motorkabels. berprfen
Sie die Lastverhltnisse. Rcksetzen des Alarms nur nach Netz-Aus.
WARNUNG/ALARM 17, Steuerwort-Timeout:
In Par. 8-04 wurde eine Timeout-Funktion aktiviert, und die in Par. 8-03
eingestellte Zeit wurde berschritten (Kommunikationsfehler).
Die Warnung wird nur angezeigt, wenn Par. 8-04 NICHT auf AUS gesetzt
Wenn Par. 8-04 auf Stopp und Alarm eingestellt ist, erscheint eine Warnung, und der Frequenzumrichter fhrt herunter, bis er mit einem Alarm
abschaltet.
Erhhen Sie gegebenenfalls den Wert in Par. 8-03 Steuerwort Timeout-
Zeit.
grenzwert (siehe Tabelle) sinkt, prft der Frequenzumrichter, ob eine
WARNUNG 23, Interne Lfter:
externe 24 V-Versorgung angeschlossen ist.
Die Funktion ist ein zustzlicher Schutz, mit der geprft wird, ob Lfter
Wenn keine externe 24 V-Versorgung angeschlossen ist, schaltet der
vorhanden sind und laufen. Die Warnung kann in Par. 14-53 Lfterber-
Frequenzumrichter nach einer festgelegten Zeit (gerteabhngig) ab.
wachung deaktiviert [0] werden.
berprfen Sie die Netzspannung und die Einstellungen in Par. 14-1*.
WARNUNG 24, Externe Lfter:
WARNUNG/ALARM 9, Wechselrichterberlast:
Die Funktion ist ein zustzlicher Schutz, mit der geprft wird, ob Lfter
Der Frequenzumrichter schaltet aufgrund von berlastung (zu hoher
vorhanden sind und laufen. Die Warnung kann in Par. 14-53 Lfterber-
Strom ber zu lange Zeit, vgl. Typenschild/Motorstrom) gleich ab. War-
wachung deaktiviert [0] werden.
nung bei 98 %, Abschaltung bei 100 %. Alarm kann erst quittiert werden,
WARNUNG 25, Bremswiderstand Kurzschluss:
wenn der Wert unter 90 % gefallen ist.
WARNUNG: Bei einem Kurzschluss im Bremskreis wird die Bremselektro-
(Aktuelle berlastung kann in Par. 16-35 berprft werden.)
nik nicht mehr angesteuert, wodurch generatorisches Bremsen nicht
WARNUNG/ALARM 10, Motortemperatur ETR:
mehr mglich ist! Schalten Sie den Frequenzumrichter aus, und berpr-
Die ETR-Funktion hat eine thermische berlastung des Motors errechnet.
fen Sie den Bremswiderstand (siehe Par. 2-15 Bremswiderstand Test).
In Par. 1-90 kann das thermische berlast-Relais (ETR) aktiviert werden.
ALARM/WARNUNG 26, Bremswiderstand Leistungsgrenze:
Der Motor ist zu lange Zeit mit mehr als 100 % belastet worden. ber-
Die zum Bremswiderstand whrend der letzten 120 s bertragene Leis-
prfen Sie die Motortemperatur und die Parameter 1-24 und 1-90.
tung bersteigt dessen Grenzwert (bertragene Bremsleistung ist hher
WARNUNG/ ALARM 11, Motor Thermistor:
als 90 %). berprfen Sie Motor/Last, die Rampen in Par. 3-** und die
Der Thermistor hat ausgelst bzw. die Verbindung zum Thermistor ist
Leistungsdaten des Widerstands in Par. 2-11, 2-12, 2-13.
unterbrochen. In Par. 1-90 kann das thermische berlast-Relais (ETR)
ALARM/WARNUNG 27, Bremse IGBT-Fehler:
aktiviert werden. berprfen Sie die Verbindung zwischen Klemme 53/54
Whrend des Betriebs wird der Bremstransistor berwacht. Bei einem
(analoger Spannungseingang) und Klemme 50 (10-V-Eingang) bzw. zwi-
Kurzschluss wird die Bremsfunktion abgebrochen und die Warnung aus-
schen Klemme 18/19 (digitaler Eingang, nur PNP) und Klemme 50. Wenn
gegeben. Der Frequenzumrichter kann weiterhin betrieben werden, auf-
ein KTY-Sensor benutzt wird, prfen Sie, ob der Anschluss zwischen
grund des Kurzschlusses wird jedoch eine hohe Leistung an den
Klemme 54 und 55 korrekt ist.
Bremswiderstand abgegeben, auch wenn dieser nicht gebremst wird.
WARNUNG/ ALARM 12, Drehmomentgrenze:
Schalten Sie den Frequenzumrichter ab, und bauen Sie den Bremswider-
Das Drehmoment ist hher als der Wert in Parameter 4-16 (bei motor-
stand aus.
ischem Betrieb) bzw. in Parameter 4-17 (bei generatorischem Betrieb).
Dieser Alarm bzw. diese Warnung kann ebenfalls auftreten, wenn der
berprfen Sie Motor/Last und Par. 4-16, 4-17 und 4-25.
Bremswiderstand berhitzt. Klemme 104 bis 106 sind als Bremswider-
stand verfgbar. Zu Klixon-Eingngen siehe Abschnitt Temperaturschal-
WARNUNG/ALARM 13, berstrom:

Die Spitzenstromgrenze des Wechselrichters (ca. 200 % des Nennstroms)
wurde berschritten. Die Warnung wird ca. 8 bis 12 Sekunden lang angezeigt. Danach schaltet der Umrichter ab und gibt einen Alarm aus.
berprfen Sie Motor/Last und die Motordaten in Par. 1-**.
Bei Auswahl der erweiterten mechanischen Bremssteuerung kann die Ab-
ter Bremswiderstand.
Warnung: Bei einem Kurzschluss des Bremstransistors
besteht das Risiko einer erheblichen Leistungsbertragung zum Bremswiderstand (Brandgefahr!).
schaltung extern zurckgesetzt werden.

ALARM 14, Erdschluss:
ALARM/WARNUNG 28, Bremstest Fehler:
Es wurde ein Erdschluss zwischen einer Ausgangsphase und Erde fest-
Es wurde ein Fehler am Bremskreis festgestellt. berprfen Sie Brems-
gestellt. berprfen Sie die Isolation des Motors und des Motorkabels.
widerstand und Verdrahtung. Siehe auch Par. 2-15.
Der Alarm kann nur nach Netz-Aus quittiert werden.
87

ALARM 29, Umrichter bertemperatur:
519 Fehlende oder ungltige BarCode-Daten in EEPROM
Bei Schutzart IP20 oder IP21/NEMA 1 liegt die Abschaltgrenze fr die
1024 1279 CAN-Telegramm kann nicht gesendet wer-
Khlkrpertemperatur bei 95 C 5 C. Der Temperaturfehler kann erst
den. (1027 deutet auf mglichen Hardwarefehler hin)
dann quittiert werden, wenn die Khlkrpertemperatur 70 C +5 oC wie-
1281 Timeout beim digitalen Signalprozessor
der unterschritten hat.
1282 Die Versionen der Power Micro-Software stimmen nicht
Mgliche Ursachen:
-
Umgebungstemperatur zu hoch
Motorkabel zu lang
berein
1283 Die Versionen der EEPROM-Leistungsdaten stimmen
nicht berein
1284 Softwareversion des digitalen Signalprozessors kann
ALARM 30, Motorphase U fehlt:
nicht gelesen werden
Es wurde festgestellt, dass die Motorphase U am Umrichterausgang fehlt.
1299 Options-Software in Steckplatz A ist zu alt
berprfen Sie die Umrichter-Ausgangsklemmen, das Motorkabel und
1300 Options-Software in Steckplatz B ist zu alt
den Motor. Rcksetzen des Alarms nur nach Netz-Aus.
1311 Options-Software in Steckplatz C0 ist zu alt
ALARM 31, Motorphase V fehlt:
1312 Options-Software in Steckplatz C1 ist zu alt
Es wurde festgestellt, dass die Motorphase V am Umrichterausgang fehlt.
1315 Options-Software in Steckplatz A nicht untersttzt (nicht
zulssig)
1316 Options-Software in Steckplatz B nicht untersttzt (nicht
ALARM 32, Motorphase W fehlt:
zulssig)
Motorphase W zwischen Frequenzumrichter und Motor fehlt.
1317 Options-Software in Steckplatz C0 nicht untersttzt
(nicht zulssig)
1318 Options-Software in Steckplatz C1 nicht untersttzt

(nicht zulssig)
ALARM 33, Inrush Fehler:
1536 Es wurde eine AOC-Ausnahme festgestellt. Fehlerbehe-
Der Frequenzumrichter ist in kurzer Zeit zu oft eingeschaltet worden.
bungsinformationen auf LCP-Konsole
berprfen Sie eine eventuell vorhandene externe 24-V-Versorgung und
1792 DSP Watchdog ist aktiv. Behebung von Fehlern bei der
den Bremswiderstand. Wie viele Einschaltzyklen pro Minute zulssig sind,
bertragung von MOC-Leistungsdaten
ist den Allgemeinen technischen Daten zu entnehmen.
2049 Leistungsdaten neu gestartet
WARNUNG/ALARM 34, Feldbus-Fehler:
2315 Fehlende Software-Version von Antrieb
Der Feldbus auf der Optionskarte funktioniert nicht. Siehe Beschreibung
2816 Stapelberlauf an Steuerkartenmodul
im Handbuch zur Feldbus-Option.
2817 Planung langsame Aufgaben
WARNUNG/ALARM 36, Netzausfall:
2818 Schnelle Aufgaben
In Par. 14-10 wurde eine Netzausfall-Funktion eingestellt, und es wurde
2819 Parameter-Thread
ein Netzfehler festgestellt. berprfen Sie die Netzversorgung und Par.
2820 LCP-Stapelberlauf
14-10.
2821 berlauf an der seriellen Schnittstelle
Alarm 38, interner Fehler:
2822 berlauf an der USB-Schnittstelle
Es ist ein interner Fehler aufgetreten. Wenden Sie sich an den Danfoss-
3072-512 Parameterwert liegt nicht im zulssigen Grenzwertbe-
Service. Einige typische Alarmmeldungen:
reich. Fhren Sie eine Initialisierung durch. Parameternummer, die den Alarm ausgelst hat: Ziehen Sie vom
Code den Wert 3072 ab. Beispiel: Fehlercode 3238:
0 Die serielle Kommunikationsschnittstelle kann nicht ini-
3238-3072 = 166 (auerhalb des Grenzwertbereichs)
tialisiert werden. Schwerer Hardwarefehler
5123 Option in Steckplatz A: Hardware mit Steuerkartenhard-
256 Die EEPROM-Leistungsdaten sind beschdigt oder ver-
ware nicht kompatibel
altet
5124 Option in Steckplatz B: Hardware mit Steuerkartenhard-
512 Die EEPROM-Daten der Steuerkarte sind beschdigt
ware nicht kompatibel
oder veraltet
5125 Option in Steckplatz C0: Hardware mit Steuerkarten-
513 Timeout beim Lesen von EEPROM-Daten
hardware nicht kompatibel
514 Timeout beim Lesen von EEPROM-Daten
5126 Option in Steckplatz C1: Hardware mit Steuerkarten-
515 AOC erkennt EEPROM-Daten nicht
hardware nicht kompatibel
516 Schreiben in EEPROM nicht mglich, da ein Schreibvorgang durchgefhrt wird

517 Timeout fr den Schreibvorgang
5376-623 Unzureichender Speicher

1
518 Fehler im EEPROM

WARNUNG 40, Digitalausgang 27 ist berlastet
berprfen Sie die Last an Klemme 27, oder beseitigen Sie den Kurzschluss. Prfen Sie die Parameter 5-00 und 5-01.
WARNUNG 41, Digitalausgang 29 ist berlastet:
berprfen Sie die Last an Klemme 29, oder beseitigen Sie den Kurzschluss. Prfen Sie die Parameter 5-00 und 5-02.
88
WARNUNG 42, Digitalausgang X30/6 ist berlastet:
WARNUNG 62, Ausgangsfrequenz Grenze:
berprfen Sie die Last an Klemme X30/6, oder beseitigen Sie den Kurz-
Die in Par. 4-19 eingestellte Frequenzgrenze wurde berschritten. ber-
schluss. Prfen Sie Parameter 5-32.
prfen Sie Motor/Last, die Motordaten in Par. 1-** und ggfs. bei einer
WARNUNG 42, Digitalausgang X30/7 ist berlastet:
PID-Regelung das Istwertsignal und die Regelparameter in Par. 7-**.
berprfen Sie die Last an Klemme X30/7, oder beseitigen Sie den Kurz-
ALARM 63, Mechanische Bremse Fehler:
schluss. Prfen Sie Parameter 5-33.
Der Motorstrom hat whrend der eingestellten Startverzgerung (Par.
WARNUNG 47, 24-V-Versorgung - Fehler:
1-71) nicht den Wert zum Lften der mechanischen Bremse (Par. 2-20)
Die externe 24-V-DC-Backup-Stromversorgung ist mglicherweise ber-
berschritten. ACHTUNG: Falsche Einstellungen knnen zum ffnen der
lastet. Andernfalls wenden Sie sich an Ihre Danfoss-Vertretung.
Bremse oder Absturz der Last fhren!
WARNUNG 48, 1,8-V-Versorgung - Fehler:
WARNUNG 64, Motorspannung Grenze:
Bitte wenden Sie sich an den Danfoss-Service.
Die Belastung des Motors bei dieser Drehzahl wrde eine noch hhere
Motorspannung erfordern, die vom Umrichter nicht zur Verfgung gestellt
WARNUNG 49, Drehzahlgrenze:

Die aktuelle Motordrehzahl unter- oder berschreitet die Einstellungen in
werden kann.
Par.4-11 und 4-13. berprfen Sie Motor/Last und die Einstellungen in
WARNUNG/ALARM/ABSCHALTUNG 65, Steuerkarte bertem-
den Parametern.
peratur:
Es wurde eine bertemperatur an der Steuerkarte festgestellt. berpr-
ALARM 50, AMA-Kalibrierungsfehler:

ALARM 51, AMA-Motordaten berprfen:
Bitte berprfen Sie die Verschaltung am Motorklemmbrett und die Einstellung der Motordaten in Par. 1-20 bis 1-24.
ALARM 52, AMA Motornennstrom berprfen:
Bitte berprfen Sie die Verschaltung am Motorklemmbrett und die Einstellung der Motordaten in Par. 1-20 bis 1-24.
ALARM 53, AMA-Motor zu gro:
fen Sie die Umgebungsbedingungen und die eingebauten Khllfter.
WARNUNG 66, Temperatur zu niedrig:

Die Temperatur im Frequenzumrichter ist kleiner als 0 C. berprfen Sie
die Umgebungsbedingungen. Da auch ein Ausfall der Temperaturfhler
nicht ausgeschlossen werden kann, laufen die eingebauten Lfter auf
max. Drehzahl.
ALARM 67, Optionen neu:
Eine oder mehrere Optionen sind seit dem letzten Netz-Ein hinzugefgt
oder entfernt worden. Siehe auch Par. 15-6*.
Bitte berprfen Sie die Leistung des Motors am Typenschild und die
Einstellungen in Par. 1-20. Wenn der Motor mehrere Gren kleiner als
der Umrichter ist, kann keine AMA durchgefhrt werden.
ALARM 68, Sicherer Stopp:

Die Funktion Sicherer Stopp wurde durch die Steuerklemme 37 aktiviert
(Signal 0 V). Um den Betrieb wieder aufzunehmen, legen Sie 24 VDC an
ALARM 54, AMA-Motor zu klein:
Kl. 37, und setzen Sie den Alarm zurck (ber Bus, Digitaleingang oder
Bitte berprfen Sie die Leistung des Motors am Typenschild und die
durch Drcken von [RESET]).
Einstellungen in Par. 1-20. Wenn der Motor mehrere Gren kleiner als
der Umrichter ist, kann keine AMA durchgefhrt werden.
WARNUNG 68, Sicherer Stopp:

Die Funktion Sicherer Stopp wurde durch die Steuerklemme 37 aktiviert
ALARM 55, AMA-Daten auerhalb des Bereichs:
(Signal 0 V). Nach Deaktivieren des sicheren Stopps wird der Normalbe-
Die gefundenen Parameterwerte vom Motor liegen auerhalb des zuls-
trieb wieder aufgenommen. Warnung: Automatischer Wiederanlauf er-
sigen Bereichs. berprfen Sie die Motordaten in Par. 1-20 bis 1-25.
folgt!
ALARM 56, AMA Abbruch:
ALARM 70, Ungltige FC-Konfiguration:
Die AMA wurde durch den Benutzer abgebrochen.
Die aktuelle Kombination aus Steuerkarte und Leistungskarte ist ungltig.
ALARM 57, AMA-Timeout:
ALARM 71, PTC 1 Sicherer Stopp:
Die AMA-Funktion wurde in Par. 1-29 aktiviert, jedoch wurde kein Start-
Sicherer Stopp wurde von der MCB 112 PTC-Thermistorkarte aktiviert
signal (z. B. [Hand-on]-Taste) gegeben. Im Regelfall ist dies jedoch nicht
(Motor zu warm). Normaler Betrieb kann wieder aufgenommen werden,
kritisch.
wenn die MCB 112 wieder 24 V DC an Kl. 37 anlegt (wenn die Motor-
ALARM 58, AMA - Interner Fehler:
temperatur einen akzeptablen Wert erreicht) und wenn der Digitalein-
gang von der MCB 112 deaktiviert wird. Wenn dies geschieht, muss ein
Reset-Signal (ber Bus, Digitalein-/-ausgang oder durch Drcken von
WARNUNG 59, Stromgrenze:

Der Ausgangsstrom hat den Grenzwert in Par. 4-18 berschritten und der
Strom wird begrenzt. Bitte wenden Sie sich an den Danfoss-Service.
[Reset]) gesendet werden.

WARNUNG 71, PTC 1 Sicherer Stopp:
Sicherer Stopp wurde von der MCB 112 PTC-Thermistorkarte aktiviert
WARNUNG 61, Drehgeber-Fehler:

Eine Abweichung zwischen der berechneten Drehzahl und der Drehzahlmessung vom Istwertgeber. Die Einstellung Warnung/Alarm/Deaktivierung fr diese Funktion erfolgt in Par. 4-30. In Par. 4-31 wird die
akzeptierte Abweichung eingestellt und die Zeit, wie lange der Drehzahlfehler berschritten sein muss, in Par. 4-32. Whrend eines Inbetriebnahmevorgangs kann die Funktion wirksam sein.
(Motor zu warm). Normaler Betrieb kann wieder aufgenommen werden,

wenn die MCB 112 wieder 24 V DC an Kl. 37 anlegt (wenn die Motortemperatur einen akzeptablen Wert erreicht) und wenn der Digitaleingang von der MCB 112 deaktiviert wird. Warnung: Automatischer
Wiederanlauf erfolgt.
ALARM 72, Gefhrlicher Fehler:
Sicherer Stopp mit Abschaltblockierung. Unerwartete Signalpegel bei sicherem Stopp und Digitaleingang von der MCB 112 PTC-Thermistorkarte.
89

ALARM 80, Initialisiert:
Der Frequenzumrichter wurde manuell (3-Finger-Methode) oder ber
Par. 14-22 initialisiert (Werkseinstellung der Parameter laden).
ALARM 90, Drehgeber Fehler:
berprfen Sie die Verbindung zur Drehgeberoption, und ersetzen Sie die
MCB 102 oder MCB 103, falls erforderlich.
ALARM 91, Falsche Einstellungen fr Analogeingang 54:
Schalter S202 muss auf U (Spannungseingang) eingestellt sein, wenn
ein KTY-Thermistor angeschlossen ist.
ALARM 250, Neues Ersatzteil:
Die Leistungs-/SMPS-Karte wurde ausgetauscht. Der Typencode des Frequenzumrichters muss im EEPROM wiederhergestellt werden. Whlen Sie
den richtigen Typencode in Par. 14-23 vom Typenschild des Gerts. Whlen Sie abschlieend unbedingt In EEPROM speichern.
ALARM 251, Typencode neu:
Der Frequenzumrichter hat einen neuen Typencode.
90
Index
Index
2
24 V Dc Backup
A
Abgeschirmt
36
Abkrzungen
Ableitstrom
Abmessungen
17
Abschirmblech
25
Alarmmeldungen
83
Allgemeine Warnung
Ama
38
Analogausgang
79
Analogeingnge
78
Ausbrechen Von Zustzlichen ffnungen Fr Kabeldurchfhrungen
22
Ausgangsleistung (u, V, W)
77
Autom. Motoranpassung
46
Automatische Motoranpassung (ama)
38
B
Bremssteuerung
87
D
Dc-spannung
86
Devicenet
Digitalausgang
79
Digitaleingnge:
77
Drehmomentkennlinie
77
Drehzahl Auf/ab
34
E
32, 35
Entsorgungshinweise
Etr
87
F
Fehlerstrom-schutzeinrichtungen
G
Grafikdisplay
41
H
Hauptreaktanz
46
I
Installation Nebeneinander
16
Ip21 / Typ 1
K
Kabellngen Und -querschnitte
80
Keine Ul-konformitt
28
Klemmen
35
Kty-sensor
87
Khlbedingungen
16
L
Lc-filter
27
Lcp 101
42
91
Index
Lcp 102
41
Lcp-bedieneinheit
41
Leds
41, 42
M
Max. Sollwert
47
Mct 10
Mechanische Bremssteuerung
40
16
Minimaler Sollwert
47
Motoranschluss
25
Motorausgang
77
Motornenndrehzahl, 1-25
45
Motornennfrequenz
45
Motornennleistung
44
Motornennspannung
45
Motornennspannung, 1-22
44
Motornennstrom
45
Motor-typenschild
38
Motor-berlastschutz
81
N
Netzanschluss
22
Netzversorgung (l1, L2, L3)
77
Numerischen Lcp-bedieneinheit
42
Numerisches Display
42
P
Parallelschaltung Von Motoren
40
Potentiometer-sollwert
34
Profibus
Puls Start/stopp
33
Puls-/drehgebereingnge
79
R
Rampenzeit Ab 1
47
Rampenzeit Auf 1
47
Relaisausgnge
80
Reparaturarbeiten
S
Schalter S201, S202 Und S801
36
Schutz
28
Schutz Und Funktionen
81
Serielle Schnittstelle
80
Sicherer Stopp
Sicherheitshinweise
Sicherungen
28
Spannungsbereich
77
Spannungssollwert ber Potentiometer
34
Sprache
44
Sprachpaket 2
44
Sprachpakets 1
44
Sprachpakets 3
44
Sprachpakets 4
44
Standardeinstellungen
48
Start/stopp
33
Statorstreureaktanz
46
Steueranschlsse
32
Steuerkabel
35, 36
Steuerkarte, +10 V Dc-ausgang
79
Steuerkarte, 24 V- Dc-ausgang
79
Steuerkarte, Rs 485 Serielle Schnittstelle
79
Steuerkarte, Usb (serielle Schnittstelle)
80
92
Index
Steuerkartenleistung
81
Steuerungseigenschaften
81
Symbole
T
40
Typenschild
38
Typenschilddaten
38
U
Umgebung
81
Unerwarteten Anlaufs
W
Warnungen
83
Wellenleistungsniveau
Z
Zugang Zu Den Steuerklemmen
31
Zulassungen
Zustandsmeldungen
41
Zwischenkreis
86
93
Equipment for water

and steam supply

for shell hot water generators
E016
Version 2 (07/09)
Contents
1
Safety .......................................................................................................................................................................... 2
Assembly .................................................................................................................................................................... 3
8.1
Three-way regulator valve assembly (in case of return flow temperature maintenance).............................................. 3
8.2
Assembly instructions for return flow temperature boosting ......................................................................................... 4
8.2.1
Orifice........................................................................................................................................................................... 4
8.2.2
Flow monitor and temperature limiter ........................................................................................................................... 5
10
Controls ...................................................................................................................................................................... 5
11
Start-up ....................................................................................................................................................................... 5
12
13
14
C014 Shell boilers for the generation of hot water
Pump operating instructions
Operating instructions for the motor-driven three-way control valve (in the event of return flow temperature
maintenance)
Operating Instructions on the motorized shut-off valve (in case of return flow temperature boosting)
The return flow temperature safeguard on a hot water generator is used to prevent excessive temperature differences
between the boiler forward and return flows and boiler return flow temperatures that are too low, in order to avoid the
Page 1 of 6

E016
Version 2 (07/09)
temperature falling below the dew point and the resultant corrosion in the boiler. The temperatures may not fall below the
values for boiler forward and return flow temperatures laid down in the order confirmation (except for start-up operation).
Safety
The return flow temperature safeguard on a hot water generator can be realised by maintaining or raising the return flow
temperature.
Maintaining the return flow temperature:

The system for maintaining the return flow temperature consists of the main components boiler circulating pump, motordriven three-way regulating valve and return flow temperature regulator (see Data Sheet DA114). This type of system
can only be used if a hydraulic diplexer or a differential pressure-free distributor (supply flow distributor and return flow
collector with hydraulic balancer) are provided on the network side. The boiler circulating pump is responsible for
pumping round the water in the boiler circle (boiler diplexer boiler, or boilers supply flow distributor return flow
collector boiler). The heat produced in the boiler is made available to the diplexer or the supply flow distributor. It is
crucially important for the working life of the boiler that, during operation of the firing, the boiler circulating pump is
running. If there is a fault in the boiler circulating pump, the burner must be switched off. If this is not done, the heat
produced in the boiler will not be taken away, resulting in local overheating, which can quickly cause boiler damage.
The motor-driven three-way regulating valve is controlled by the return flow temperature regulator. If the network return
flow temperature falls, a part-flow from the supply flow of the boiler is mixed with the return flow to the boiler in order to
reach the set boiler return flow temperature. In extreme cases and if the boiler is started up from cold, the motor-driven
three-way regulating valve can be opened completely in the direction of the boiler circuit.
Raising the return flow temperature.

The system for raising the return flow temperature consists of the main components of a booster pump and return flow
temperature regulator (see Data Sheet DA115). this type of system is logical if only a supply flow distributor and a return
flow collector are used on the network side. Network pumps are responsible for removing the heat from the boiler.
the booster pump is controlled by the return flow temperature regulator. In the simplest cases, the booster pump is
switched parallel to the burner. This means that the booster pump always runs when the firing is also in operation.
Page 2 of 6

E016
Version 2 (07/09)
Assembly
If the return flow temperature safeguard is not supplied as a completely assembled module, the pipeline diagrams for
maintaining the return flow temperature DA114 or for raising the return flow temperature DA115 must be followed during
installation. When installing all valves, pay attention to the direction of flow.
8.1
Three-way regulator valve assembly (in case of return flow temperature maintenance)
The position of the connections on the water side should particularly be observed during assembly and electrical connection
of the motorized three-way regulator valve with return flow temperature maintenance:
A
network return flow
admixing line
AB
boiler return flow
If the piping parts are not delivered by Loos International it must be observed that the distance between the admixing line
orifice and the boiler inlet is dimensioned sufficiently to ensure complete water mixing upstream of the boiler inlet and the
formation of streaks is avoided.
Page 3 of 6

E016
Version 2 (07/09)
8.2
Assembly instructions for return flow temperature boosting
D13.020
D13.004
D13.020
D13.008
A
D13.003
D13.004
D13.006
B
D13.005
D13.020
D13.004
D13.020
D13.008
D10.004
D10.013
D10.004
Temperature limiter
D13.005
Shut-off valve
D10.013
Flow monitor
D13.006
Lifting pump
D13.003
Shut-off valve
D13.008
Orifice (if available)
D13.004
Non-return valve
D13.020
Seal
Case A
Nominal diameters of lifting pump and

admixing line are equal
Fall B
Nominal diameters of lifting pump and

admixing line are different
Figure 1: schematic diagram of return flow temperature boosting
8.2.1
Orifice
In some cases the return flow temperature boosting equipment contains an orifice (D13.008), see Figure 1. This orifice
should be installed directly downstream of the pump (in flow direction) between two seals. In case A (equal nominal width of
lifting pump and admixing line) it is installed between the flange of the admixing pump and the non-return valve. In case B
(different nominal width of lifting pump and admixing line) the orifice is installed between flange and admixing pump and the
flange adapter.
Page 4 of 6

E016
Version 2 (07/09)
Important! Ensure that the orifice is installed centrally between the two flanges.
8.2.2
Flow monitor and temperature limiter
The flow monitor (D10.013) and the temperate limiter (D10.004) must be installed upstream of the admixing line branching
point (see Figure 1). Installation of these safety devices upstream of the point where the admixing line branches off from the
supply flow line is the only way to ensure monitoring of the necessary minimum flow and the maximum admissible
temperature even with exclusive flow in the boiler circuit when the motorized shut-off valve is closed during return flow.
Warning! Faulty installation of the flow monitor or temperature limiter can cause severe damage to the boiler.
The consequence can be total loss of the boiler. In extreme cases, severe damage to the system may result and
people could suffer fatal injuries.
Electrical Installation
10 Controls
Note: If the system's controls are not supplied by Loos International, the system must be operated according to
the operating instructions for the controls that are actually used.
Notes on the controls are given in the circuit diagram and the operating instructions for the controls and process technology
in Registers G and/or H.
11 Start-up

Important! If the return flow temperature safeguard works by raising the return flow temperature, take care
during initial commissioning that the boiler is powered up at the beginning in its own boiler circulation at burner
low load and that the shut-off valves to the network are only opened slowly afterwards, so that only as much cold
network water flows into the boiler to prevent the temperature falling below the minimum boiler intake
temperature.

repair:
Observation/fault:
Mean boiler return flow temperature is not reached
Cause
Repair
Performance regulation on released for low load
Release performance regulation in the regulation

menu
By whom?
Page 5 of 6

E016
Version 2 (07/09)
Cause
Repair
Too much heat being removed from boiler
Throttle return flow water volume
Observation/fault:
By whom?
Return flow temperature too low, or return flow temperature monitoring triggered
Cause
Repair
Check mixer pump or boiler circulating pump.
By whom?
If using return flow temperature maintenance, check

the motor-driven three-way regulating valve.

For general maintenance instructions, please read the Operating Instructions:
the relevant operating instructions of the manufacturer of the valves and pumps installed in the return flow temperature
safeguard system, listed in Register K
Page 6 of 6
1146.81/8-10
Etaline
In-line Pumps
Order No.:
Type Series:
Etaline
These
operating
instructions
contain
fundamental information and precautionary
notes. Please read the manual thoroughly prior
to installation of unit, electrical connection and
commissioning. It is imperative to comply with all
other operating instructions referring to
components of individual units.
This manual shall always be kept close to the
units location of operation or directly on the
pump set.
Etaline
D
GB
F
E
P
I
CZ
DK
EST
H
LT
LV
N
NL
PL
S
FIN
SK
SLO
GR
Erklrung des Herstellers im Sinne der EU-Maschinenrichtlinie 98/37/EG

Declaration by the manufacturer as defined by machinery directive 98/37/EC
Dclaration du fabricant conformment la directive CE relative aux machines 98/37/CE
Declaracin del fabricante conforme con la Directiva UE sobre mquinas 98/37/UE
Declarao do Fabricante segundo a directiva CE 98/37/CE
Dichiarazione del costruttore ai sensi della direttiva CE 98/37/CE relativa a macchinari
Prohlen vrobce ve smyslu smrnice EU pro stroje 98/37/EU
Fabrikantens erklring i henhold til EU--lovgivning om maskiner 98/37/EU,
Tootja deklaratsioon EU-seadmete direktiivi 98/37/EC jrgi
Gyrti nyilatkozat 98/37 EU-irnyelv rtelmben
Gamintojo pareikimas pagal ES 98/37/EG Main direktyvos II B priedo nuostatas
Raotaja deklarcija saska ar manbves direktvu 98/37/ES
Erklring fra produsent iflge EUs--maskindirektiv 98/37/EC
Verklaring van de fabrikant inzake richtlijn 98/37/EG, voor machines
Deklaracja producenta zgodnie z dyrektywa UE dotyczaca urzadzen nr 98/37/UE
Tillverkardeklaration enligt EU:s Maskindirektiv 98/37/EC
Valmistajanvakuutus EU-konedirektiivin 98/37/ETY mukaan
Prehlsenie vrobcu v zmysle Smernice E 98/37/EG pre stroje
Izjava proizvajalca kot definira ES direktiva 98/37/ES
D
GB
F
E
P
I
CZ
DK
EST
H
Hiermit erklren wir, dass die Pumpe

Herewith we declare that the pump
Par la prsente, nous dclarons que la pompe
Por la presente declaramos que la bomba
Com a presente, declaramos que a bomba
Si dichiara che la pompa
Tmto prohlaujeme, e erpadlo
Hermed erklres, at pumpetype
Kinnitame, et pump
Igazol juk, hogy a szivatty
LT
LV
N
NL
PL
S
FIN
SK
SLO
GR
iuo ratu mes pareikiame, kad siurblys

Ar o deklarjm, ka sknis
Herved erklrer vi at pumpen
Hiermee verklaren wij, dat de pomp
Niniejszym deklarujemy, e pompa
Hrmed frskrar vi att pumpen
Vakuutamme, ett pumppu
Tmto prehlasujeme, e erpadlo
Izjavljamo, da je rpalka
m
Etaline
D
zum Einbau in eine Maschine 1) / Zusammenbau mit anderen Maschinen zu einer Maschine 1) bestimmt ist. Ihre
Inbetriebnahme ist solange untersagt, bis festgestellt wurde, da die Maschine, in die diese Pumpe eingebaut werden
soll, bzw. mit der diese Pumpe zusammengebaut werden soll, den Bestimmungen der EU--Richtlinie in der jeweils
gltigen Fassung entspricht.
GB
is intended to be incorporated into machinery 1) or assembled with other machinery to constitute machinery 1) covered
by this directive and must not be put into service until the machinery into which it is be incorporated or with which it is
to be assembled has been declared in conformity with the provisions of the directive in its current version.
est destine tre incorpore dans une machine 1) / tre assemble avec dautres machines afin de constituer une
machine 1) et que sa mise en service est interdite avant que la machine dans laquelle elle sera incorpore / avec laquelle
elle sera assemble nait t dclare conforme aux dispositions de la directive, dans la version respective en vigueur.
Etaline
E
est destinada a ser incorporada en una mquina 1) /a ser ensamblada con otras mquinas para conformar una
mquina 1) y que su puesta en servicio est prohibida antes de que la mquina en la que vaya a ser incorporada o con la
que vaya a ser ensamblada haya sido declarada conforme con las disposiciones de la Directiva en su redaccin vigente.
se destina a ser instalada numa mquina 1) / ser montada com outras mquinas de modo a formar uma mquina 1)
coberta por esta directiva e que proibida a sua colocao em servio da mesma antes de a mquina em que essa
bomba vier a ser incorporada/montada ser declarada em conformidade com o disposto na directiva CE na sua verso
corrente.
destinata al montaggio in una macchina 1) / allassemblaggio con altre macchine a formare un macchinario 1) e che
la sua messa in marcia vietata fin quando non sar stata accertata la conformit del macchinario, nel quale questa
pompa viene montata o col quale detta pompa deve venir assiemata, alle disposizioni delle direttiva CE nella versione
vigente.
CZ
je ureno pro mont do stroje 1) / pro mont s jinm strojem pro kompletaci stroje 1). Jeho uveden do provozu je
zakzno do t doby, dokud nebude zjiteno, e stroj, ve kterm m bt erpadlo zamontovno, pop. kter m bt s
tmto erpadlem smontovn, odpovd ustanovenm smrnice EU v prv platnm znn.
DK
er bestemt til indbygning i en maskine 1) / samling med andre maskiner med henblik p at udgre en maskine 1) og at
igangstningen forbydes indtil det er konstateret, at maskinen, som vor pumpe skal monteres i, svarer til
EU--bestemmelserne af EU--lovgivningen til en hver tid gyldig udgave.
EST
on meldud paigaldamiseks seadmele 1) / komplekteerimiseks muude seadmetega heks seadmeks 1). Pumba
kasutuselevtt on keelatud kuni on selgunud, et seade kuhu pump paigaldatakse vi kuhu pump hendatakse , vastab
EU jusolevatele normidele
egy gpbe trtn beptsre 1) / egy msik gppel trtn sszeptsre 1) alkalmas. zembehelyezse mindaddig
tiltott, mg megllaptsra nem kerl, hogy a gp, ahova a szivatty kerl, illetve amivel a szivatty sszeptsre ker,
l a kvetkez rendelkezseknek a mindenkor rvnyes vltozat szerint megfelel
LT
numatytas taisyti mainoje 1) / sumontuoti kartu su kitomis mainomis sukuriant vien main 1). Atiduoti naudoti
neleidiama tol, kol nebus nustatyta, kad maina, kuri turi bti taisytas is siurblys arba su kuria is siurblys bus kartu
montuojamas, atitinka ES direktyvos galiojanios redakcijos nuostatas.
LV
Paredzta iebvanai iekrta 1) vai savienoanai ar citu iekrtu lai izveidotu agregtu 1) un to nedrkst nodot
ekspluatacij ldz iebvtas vai pievienotas iekrtas deklaranas brdim saska ar spk esom direktvm
er bestemt for montering i en maskin 1) / for sammenbygning med andre maskiner til en maskin 1). Igangkjring skal ikke
skje, fr det er klargjort at maskinen som pumpen skal monteres i, h.h.v. som pumpen skal bygges sammen med oppfyller
kravene i EUs retningslinjer i den til enhver tid gjeldende utgave.
NL
ertoe bestemd is, ingebouwd te worden in een machine 1) / samengebouwd wordt met andere machines tot n machine
1) en dat het in gebruik stellen verboden is, voordat vastgesteld is, dat de machine, waarin deze pomp wordt ingebouwd,
in overeenstemming met de bepalingen van de richtlijn is.
PL
jest przewidziana do zabudowy w urzdzeniu 1) / do wsplnej zabudowy z innym urzdzeniem jako cao 1).
Uruchomienie nie jest moliwe do czasu, kiedy nie zostanie stwierdzone, e urzdzenie, w ktrym ma zosta
zabudowana pompa, wzgldnie w przypadku wsplnej zabudowy pompy z tym urzdzeniem, odpowiada przepisom
wytycznych UE w wersji obowiazujcej w danej chwili
r avsedd fr inbyggnad i en maskin 1) / montering med annan maskin fr att utgra en maskin 1). Idrifttagning fr inte
ske frrn klarstllts att maskinen, i vilken pumpen skall inbyggas respektive med vilken denna pump skall
sammanbyggas, r tillverkad i verensstmmelse med EU:s ifrgavarande gllande riktlinjer.
FIN
on tarkoitettu asennettavaksi koneeseen 1) / koottavaksi muiden koneiden kanssa yhdeksi koneeksi 1). Pumpun
kyttnotto on kielletty siihen saakka, kunnes on todettu, ett kone, johon tm pumppu on tarkoitus asentaa tai johon
pumppu on tarkoitus yhdist, vastaa EU-direktiivi kulloinkin voimassa olevassa muodossa.
SK
Zabudovanie do stroja 1) / zmontovanie s inmi strojmi do jednho stroja 1) je uren. Uvedenie do prevdzky je mon
a po zisten, e mechanizmy, ktor maj by do erpadla zabudovan, prp. S erpadlom zmontovan, zodpovedaj
platnmu obsahu smernice E.
SLO
namenjena za vgradnjo v stroje 1) ali zdruitev z ostalimi stroji v enoten stroj 1). Njena uporaba je prepovedana, dokler
ni potrjeno, da stroj, v katerega naj bi bila rpalka vgrajena oz. naj bi bil z njo skupaj zdruen, ustreza doloilom direktiv
ES v njeni trenutno veljavni obliki.
GR
Etaline
Angewendete harmonisierte Normen, insbesondere

Applied harmonized standards, in particular
Normes harmonises utilises, notamment
Normas concordantes aplicadas; en especial
Normas harmonizadas utilizadas, em particula
Norme armonizzate applicate, in particolare
Pouit harmonizovan normy, zejmna
De harmoniserde standarder, der er blevet anvendt,
er i srdeleshed
EST Kohaldatud rahvusvahelised tehnilised normid, eriti
H
Alkalmazott harmonizlt szabvnyok, klnsen
D
GB
F
E
P
I
CZ
DK
Taikyti suderintieji standartai, ir ypa:

Pielietoti saskaotie standarti, piemram
Anvendte harmoniserte normer, spesielt
Gebruikte geharmoniseerde normen, in het bijzonder:
Normy zharmonizowane, a zwaszcza
Tillmpade harmoniserade standarder, speciellt
Sovelletut, harmonisoidut normit, erityisesti
Pouit harmonizovan normy, najm
Veljavnim usklajenim standardom, e posebej
j m
j,
LT
LV
N
NL
PL
S
FIN
SK
SLO
GR
EN 809, EN ISO 12100--1, EN ISO 12100--2

EN 1050
01.07.2005
KSB Aktiengesellschaft
Leiter Produktentwicklung /
Head of Product Development / Responsable Dveloppement Produits
Pumpen fr Industrietechnik /
Pumps for Industrial Applications / Pompes pour lIndustrie
KSB Aktiengesellschaft, Johann-Klein-Str. 9, D-67225 Frankenthal
1)
D
GB
F
E
P
I
CZ
DK
EST
H
Nichtzutreffendes streichen.
Delete if not applicable.
Rayer la mention inutile.
Tchese lo que no se aplica.
Ricar o que no for aplicvel.
Cancellare ci che non interessa.
Nehodc se krtnte.
Det ikke passende streges.
Mittevajalik tmmata maha.
A nem megfelelt thzni.
LT
LV
N
NL
PL
S
FIN
SK
SLO
GR
Ubraukti netinkam variant.

nevajadzgo izslgt.
Stryk det som ikke passer.
Doorhalen, wat niet van toepassing is.
Niepotrzebne skreli.
Det icke tillmpliga verstrykes.
Tarpeeton yliviivataan.
Nehodiace sa vymaza.
Prertajte, kar ne ustreza.
Etaline
Contents
Page
Declaration of Conformity
General
2
2.1
2.2
2.3
2.4
2.5
2.6
6
6
6
6
6
6
2.8
Safety
Marking of Instructions in the Manual
Personnel Qualification and Training
Non-compliance with Safety Instructions
Safety Awareness
Safety Instructions for the Operator / User
Safety Instructions for Maintenance, Inspection
and Installation Work
Unauthorised Modification and Manufacture of
Spare Parts
Unauthorised Modes of Operation
3
3.1
3.2
Transport and Interim Storage

Transport
Interim Storage / Preservation
7
7
7
4
4.1
4.2
4.3
4.4
4.5
Description of the Product and Accessories

Technical Specification
Designation
Design Details
Accessories
Noise Characteristics
7
7
7
8
8
8
5
5.1
5.2
5.3
5.4
5.5
5.5.1
5.5.2
5.5.3
Installation at Site
Safety Regulations
Checks to Be Carried out Prior to Installation
Installing the Unit
Connecting the Piping
Connection to Power Supply
Connecting the Motor
Setting the Time Relay
Checking the Direction of Rotation
8
8
8
8
8
8
9
9
9
2.7
7
7
7
Page
6
6.1
6.1.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.3
6.3.1
6.3.2
6.4
Commissioning, Start-up / Shutdown

Commissioning
Priming and Venting the Pump
Operating Limits
Temperature of Medium Handled
Switching Frequency
Minimum Flow
Density of the Medium Handled
Tightening Torques
Shutdown / Storage / Preservation
Storage of New Pumps
Measures to Be Taken for Prolonged Shutdown
Returning to Service after Storage
9
9
9
9
9
10
10
10
10
10
10
10
10
7
7.1
7.2
7.2.1
7.2.2
7.2.2.1
7.2.2.2
7.2.2.3
Maintenance / Repair
General Instructions
Maintenance / Inspection
Supervision of Operation
Lubrication and Lubricant Change
Lubrication
Grease Quality / Grease Change
Deep-groove Ball Bearings / Lubricant Quantity
-- for KSB IEC motor
Drainage / Disposal
Dismantling
Fundamental Instructions and Recommendations
Preparations for Dismantling
Pump
Mechanical Seal
Reassembly
Pump
Mechanical Seal
Motor for Etaline GN, MN
Spare Parts Stock
Interchangeability of Etaline and Etabloc
Components and Interchangeability of
Components among Each Other
Ordering Spare Parts
Recommended Spare Parts Stock for 2 Years
Continuous Operation in Accordance with
VDMA 24 296
10
10
10
10
11
11
11
Trouble-shooting
15
9
9.1
9.2
9.3
Relevant Documentation
Typical Installation Positions
Exploded Views / Lists of Components
Sectional Drawing
16
16
18
20
7.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.5
7.5.1
7.5.2
7.5.3
7.6
7.6.1
7.6.2
7.6.3
11
11
11
11
11
11
12
12
12
12
12
13
13
14
14
Etaline
1
General
Caution
This KSB pump has been developed in accordance with
state-of-the-art technology; it is manufactured with utmost care
and subject to continuous quality control.
These operating instructions are intended to facilitate
familiarisation with the pump and its designated use.
The manual contains important information for reliable, proper
and efficient operation. Compliance with the operating
instructions is of vital importance to ensure reliability and a long
service life of the pump and to avoid any risks.
These operating instructions do not take into account local
regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for
installation.
This pump / unit must not be operated beyond the limit values
specified in the technical documentation for the medium
handled, capacity, speed, density, pressure, temperature and
motor rating. Make sure that operation is in accordance with the
instructions laid down in this manual or in the contract
documentation.
The name plate indicates the type series / size, main operating
data and order / ident. No.; please quote this information in all
queries, repeat orders and particularly when ordering spare
parts.
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSBs nearest customer service centre.
Safety
These operating instructions contain fundamental information

which must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the
responsible trained personnel / operators prior to installation
and commissioning, and it must always be kept close to the
location of operation of the machine / unit for easy access.
Not only must the general safety instructions laid down in this
chapter on Safety be complied with, but also the safety
instructions outlined under specific headings.
2.1
Marking of Instructions in the Manual
The safety instructions contained in this manual whose

non-observance might cause hazards to persons are specially
marked with the symbol
general hazard sign to ISO 7000 -- 0434.

The electrical danger warning sign is
safety sign in accordance with IEC 417 -- 5036.
The word
Caution
is used to introduce safety instructions whose non-observance
may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
-- arrow indicating the direction of rotation
-- markings for fluid connections
must always be complied with and be kept in perfectly legible
condition at all times.
2.2
Personnel Qualification and Training
2.3
Non-compliance with Safety Instructions
2.4
Safety Awareness
2.5
Safety Instructions for the Operator / User
All personnel involved in the operation, maintenance,

inspection and installation of the machine must be fully qualified
to carry out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question
is not already in possession of the requisite know-how,
appropriate training and instruction must be provided. If
required, the operator may commission the manufacturer /
supplier to take care of such training. In addition, the operator
is responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.
Non-compliance with safety instructions can jeopardise the

safety of personnel, the environment and the machine itself.
Non-compliance with these safety instructions will also lead to
forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
-- failure of important machine / unit functions
-- failure of prescribed maintenance and servicing practices
-- hazard to persons by electrical, mechanical, thermal and
chemical effects
-- hazard to the environment due to leakage of hazardous
substances.
It is imperative to comply with the safety instructions contained

in this manual, the relevant national health and safety
regulations and the operators own internal work, operation and
safety regulations.
-- Any hot or cold components that could pose a hazard must

be equipped with a guard by the operator.
-- Guards which are fitted to prevent accidental contact with
moving parts (e.g. motor fan hood) must not be removed
whilst the machine is operating.
-- Leakages (e.g. at the shaft seal) of hazardous media
handled (e.g. explosive, toxic, hot) must be contained so as
to avoid any danger to persons and the environment.
Pertinent legal provisions must be adhered to.
-- Electrical hazards must be eliminated. (In this respect refer
to the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)
Etaline
2.6
Safety Instructions for Maintenance,

Inspection and Installation Work
The operator is responsible for ensuring that all maintenance,

inspection and installation work be performed by authorised,
qualified specialist personnel who are thoroughly familiar with
the manual.
The pump must have cooled down to ambient temperature,
pump pressure must have been released and the pump must
have been drained.
Work on the machine must be carried out only during standstill.
The shutdown procedure described in the manual for taking the
machine out of service must be adhered to without fail (see
chapter 6).
Pumps or pump units handling media injurious to health must
be decontaminated.
Immediately following completion of the work, all
safety-relevant and protective devices must be re-installed
and/or re-activated.
Please observe all instructions set out in chapter 6.1
Commissioning before returning the machine to service.
2.7
When transporting the pump without motor the shaft 210 must
be fixed.
1. Remove screws on cover plates 68-3, press cover plates
slightly together and remove from the drive lantern 341.
2. Slide lockwasher 931 into the shaft keyway and secure by
using hexagon head bolts 901.1.
Unauthorised Modification and

Manufacture of Spare Parts
Modifications or alterations of the machine are only permitted

after consultation with the manufacturer. Original spare parts
and accessories authorised by the manufacturer ensure safety.
The use of other parts can invalidate any liability of the
manufacturer for consequential damage.
2.8
Unauthorised Modes of Operation
3
3.1
Transport and Interim Storage

Transport
The warranty relating to the operating reliability and safety of

the pump / unit supplied is only valid if the machine is used in
accordance with its designated use as described in chapter 4.
The limits stated in the data sheet must not be exceeded under
any circumstances.
Transport of the unit requires proper preparation and handling.

Always make sure that the pump or the unit remains in
horizontal position during transport and cannot slip out of the
transport suspension arrangement. Do not use lifting sling on
the free shaft end of pump or motor eyebolt.
If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage to
property.
Fig. 2
3.2
Transport of the pump
Interim storage (indoors) / Preservation
When the unit is temporarily put into storage, only the wetted
low alloy components (e.g. grey cast iron JL10401), nodular
cast iron JS 10252), etc.) must be preserved. Commercially
available preservatives can be used for this purpose. Please
observe
the
manufacturers
instructions
for
application/removal.
The unit / pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
Caution
Protect all stored goods against humidity, dirt, vermin and
unauthorised access! All openings of the assembled unit
components are closed and must only be opened when
required during installation.
All blank parts and surfaces of the pump are oiled or greased
(silicone-free oil and grease) to protect them against corrosion.
4
4.1
Description of the Product and Accessories

Technical Specification
4.2
Designation
Single-stage, non-self-priming in-line pump for handling liquids

not chemically or mechanically aggressive to the pump
materials.
The pump designation is stated on the name plate.
Example:
Etaline G N 65 - 160 / 40 2
Type series
Casing material, for ex. JL 1040 1)
S = casing of JS 1025 2)
M = impeller of tin bronze
Stub shaft variant with
standardised motor
Pump unit size
Nom. dia. of suction/discharge nozzle
Approx. impeller diameter
Motor rating: kW x 10 (example 4.0 kW)
No. of motor poles
1)
Fig. 1
Transport of the pump unit
2)
to EN 1561 = GJL-250
to EN 1563 = GJL-400-18-LT
Etaline
4.3
Design Details
Pump
Etaline GN, MN: Single-stage, close-coupled, in-line pump,
with standardised motor to DIN 42 677. The pump shaft is
rigidly connected to the motor shaft.
Shaft seal
Uncooled mechanical seal to EN 12 756 with replaceable shaft
sleeve.
4.4
Accessories
4.5
Noise Characteristics
Pump foot for vertical installation of the motor.

Y-pipes for duplex pumps (DN 40 to DN 100).
Switchgear for single and duplex pumps.
Rated p
power
i
input
PN
(kW)
1)
Sound pressure level LpA (dB) 1)

Pump with motor
1450 1/min
2900 1/min
0.25
53
--
0.37
54
--
0.55
55
--
0.75
56
66
1.1
57
66
1.5
58
67
2.2
59
67
3.0
60
68
4.0
61
68
5.5
62
70
7.5
64
71
11.0
65
73
15.0
67
74
18.5
68
75
22.0
69
76
30.0
70
77
37.0
71
78
45.0
73
78
55.0
74
--
Measured at a distance of 1 m from the pump outline (ISO 3744)
The above noise characteristics refer to non-cavitating pump

operation in the Qopt range.
5
5.1
Installation at Site
Safety Regulations
When mounting the pump on a foot, make sure that the

foundation or bracket has sufficient strength (min. class X0 to
DIN 1045 for concrete foundations).
5.3
Installing the Pump Unit
Etaline pumps may be flanged directly into the piping

irrespective of the installation position.
Caution
For safety reasons the arrangement of motor below is
however not permitted.
Make sure that the condensation water holes in the motor are
properly positioned (see page 14). The screwed plug needs to
be changed depending on the installation position.
Motors from size 180 on pump units with horizontal motor axis
need to be supported without transmitting any stresses or
strains.
On duplex pumps, direction of flow from top to bottom is not
permitted, since the Y-pipes changeover flap does not close
completely in certain modes of operation, and the other pump
would then be subjected to reverse flow.
When changing over from one pump to the other, this
arrangement might result in damage.
5.4
Connecting the Piping
Caution
Never use the pump itself as an anchorage point for the piping.
The pump must not be subjected to any pipeline
forces and moments (for example by torsion,
thermal expansion).
The pipelines should be anchored in close proximity to the
pump and should be connected without transmitting any
stresses or strains.
With short pipelines, the nominal diameters should be at
least equal to the nominal diameters of the pump nozzles.
For long pipelines, the most economical nominal diameter
has to be determined from case to case.
Adapters to larger diameters should have a diffuser angle
of approx. 8 in order to avoid any increase in pressure
losses.
It is recommended to install check and shut-off elements
in the system, depending on the type of plant and pump.
Thermal expansions of the pipelines must be compensated by
appropriate measures so as not to impose any extra loads on the
pump exceeding the permissible pipeline forces and moments.
An excessive, impermissible increase in the
pipeline forces may cause leaks on the pump
where the medium handled can escape into the
atmosphere. Danger of life when toxic or hot media
are handled.
Electrical equipment operated in hazardous

locations must comply with the explosion
protection regulations. This is indicated on the
motor rating plate.
If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the
regulations of the test certificate supplied with the
equipment and issued by the responsible approval
authorities must be observed and complied with. The test
certificate must be kept close to the location of operation
for easy access (e.g. foremans office).
Before commissioning new installations thoroughly clean, flush

and blow through all vessels, pipelines and connections.
5.2
Connection to the power supply must be effected in

accordance with the technical regulations of the
responsible local energy supply company.
We strongly recommend to use a motor protection switch
or to connect the motors PTC resistors to a trip device.
Checks to Be Carried out Prior to

Installation
All structural work required must have been prepared in

accordance with the dimensions stated in the dimension
table / installation plan.
8
5.5
Connection to Power Supply
Connection to the power supply must be effected

by a trained electrician only.
The applicable VDE regulations 0100 and, for
explosion-proof units, 0165 must be complied
with.
Check available mains voltage against the data on the motor

rating plate and select appropriate start-up method.
Etaline
5.5.1
Motor Connection
Connect the motor in accordance with the circuit diagram in the

terminal box or as illustrated in Fig. 3 or Fig. 4.
Delta starting (low voltage)
for example for motor winding: 220--240 V / 380--420 V / Y
Fig. 3
Connection diagram for three-phase motors,

delta starting
Star starting (high voltage)

for example for motor winding: 380--420 V / 660--725 V / Y
6.1.1
Priming and Venting the Pump
Before start-up, the pump and suction line must be vented and
primed with the liquid to be pumped.
The shut-off valves in the suction and discharge lines must be
fully open before venting and starting up the pump.
Depending on the system pressure and
temperature of the medium handled hot liquid or
steam may escape or spurt out under high
pressure when opening the vent plug.
Risk of burns!
Protect the electrical components against
escaping liquid.
Caution
Dry running will result in increased wear and must be
avoided!
After having started up the pump, adjust the duty point using the
discharge-side shut-off valve.
Caution
Fig. 4
5.5.2
Connection diagram for three-phase motors,

star starting
Setting the Time Relay
Make sure that in the case of three-phase motors with star-delta

starting method switching over from star to delta will be effected
at very short intervals. Prolonged switch-over intervals will
result in pump damage.
Time relay setting for star-delta starting: <3 seconds.
Explosion-proof motors must always be connected via a motor
protection switch or, if they are fitted with PTC resistors
(thermistors), via a trip device.
Once the operating temperature has been reached and/or in

the event of leakage at the joint between discharge cover 163
and volute casing 102, switch off the unit and re-tighten the
hexagon nuts 920.1 or 920.2 (see 6.2.5).
Depending on the pumps or the systems
operating mode the pump may run very hot.
Do not touch the pump, risk of burns!
When switching off the pump, make sure that the unit runs
smoothly down to a standstill.
In the event of frost during prolonged shutdowns, the pump
must be drained or otherwise protected against freezing.
6.2
6.2.1
Operating Limits
Temperature of the Medium Handled
Caution
Do not operate the pump at temperatures exceeding those
specified on the data sheet or the name plate.
5.5.3
Checking the Direction of Rotation
The motors direction of rotation must correspond to the

direction indicated by the arrow on the pumps volute casing
(clockwise seen from the motor end). This can be verified by
switching the pump on and then off again immediately.
If the unit runs in the wrong direction of rotation, interchange two
of the three phases L1, L2 or L3 of the power supply cable of
the motor terminal box.
6
6.1
Commissioning, Start-up / Shutdown

Commissioning
Caution
Before starting up the pump make sure that
-- the lockwashers 931 have been withdrawn from the shaft
keyway and fastened using hexagon head bolts 901.1 (see
Fig. 6);
-- the pump unit has been properly connected to the electric
power supply and is equipped with all protection devices;
-- the pump has been primed with the liquid to be pumped;
-- the direction of rotation has been checked;
-- all auxiliary connections have been properly connected.
6.2.2
Switching Frequency
6.2.3
Minimum Flow
6.2.4
Density of the Medium Handled
To prevent high temperature increases in the motor and

excessive loads on the pump, motor, seal elements and
bearings, the switching frequency should not exceed 15
start-ups per hour.
If the type of plant permits operation of the pump against a

closed discharge-side shut-off valve, the following minimum
flow rates are required during this time at the temperatures
stated:
t --30 to +70 C 15 % of Qopt
t >70 to + 140 C 25 % of Qopt.
The power input of the pump will increase in proportion to the

density of the medium handled. To avoid overloading of the
motor and pump, the density of the medium must comply with
the data specified on the purchase order.
Etaline
6.2.5
Tightening Torques
Version with clamped
discharge cover
2. The pump is dismantled and stored

Before putting the pump into storage carry out all checks
specified in 7.1. Then apply appropriate preservatives:
-- Spray-coat the inside wall of the pump casing, and in
particular the impeller clearance areas, with a
preservative. Spray the preservative through the suction
and discharge nozzles. It is advisable to close the nozzles
(for ex. with plastic caps or similar).
6.4
Returning to Service after Storage
Before returning the pump to service carry out all checks and
maintenance work specified in sections 7.1 and 7.2.
In addition, the instructions laid down in the sections
on Commissioning (6.1) and Operating Limits (6.2)
must be observed.
Fig. 5
Bolt/nut tightening points on the pump unit
Item
Thread size
mm
920.1
920
1
920 2
920.2
920.3
M 10
40
M 12
55
M 12 x 1,5
25
M 24 x 1,5
85
M 30 x 1,5
140
920.5
Tightening torque
MA Nm
901.1
M6
920.4
M8
15
M 10
30
M 12
45
M 16
80
M6
10
M8
25
M 10
40
914.1
6.3
Storage of New Pumps
-- New pumps are supplied by our factory duly prepared for

storage.
Maximum protection for up to 12 months, if the pump is
properly stored indoors.
-- Store the pump in a dry location.
6.3.2
Measures to Be Taken for Prolonged

Shutdown
1. The pump remains installed; operation check run

In order to make sure that the pump is always ready for instant start-up and to prevent the formation of deposits within
the pump and the pump intake area, start up the pump set
regularly once a month or once every 3 months for a short
time (approx. 5 minutes) during prolonged shutdown
periods. Prior to an operation check run ensure that there is
sufficient liquid available for operating the pump.
10
7
7.1
Maintenance / Repair
General Instructions
The operator is responsible for ensuring that all maintenance,

inspection and installation work is carried out by authorised,
duly qualified staff who are thoroughly familiar with these
A regular maintenance schedule will help avoid expensive
repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure and
work.
Work on the unit must only be carried out with the
electrical connections disconnected. Make sure
that the pump set cannot be switched on
accidentally (danger of life!).
Pumps handling liquids posing health hazards
must be decontaminated. When draining the
medium see to it that there is no risk to persons or
the environment. All relevant laws must be
adhered to.
Shutdown / Storage / Preservation
Each KSB pump leaves the factory carefully assembled. If

commissioning is to take place some time after delivery, we
recommend that the following measures be taken for pump
storage.
6.3.1
Upon completion of the work, all safety-related and

protective equipment must be properly refitted and/or
re-activated before starting the pump set.
7.2
7.2.1
Maintenance / Inspection
Supervision of Operation
Caution
The pump should run quietly and free from vibrations at all
times.
The pump must never be allowed to run dry.
The room temperature must never rise above 40 C.
The bearing temperature may exceed room temperature by up
to 50 C but must never rise above 90 C.
Do not run the pump against a closed shut-off valve
for prolonged periods of time so as to avoid heating up
of the medium pumped.
For required minimum flows please refer to section 6.2.3.
During pump operation the shut-off valve in the suction line must not be closed.
The mechanical seal leaks only slightly or invisibly (vapour)
during operation. It is maintenance-free.
Etaline
Any stand-by pumps installed should be switched on and then
immediately off again once a week to keep them operational.
Attention should be paid to the correct functioning of the auxiliary connections.
7.2.2 Lubrication and Lubricant Change

7.2.2.1 Lubrication
The rolling element bearings of the KSB IEC motor are

grease-lubricated. The lubricant change intervals as well as the
required quantity and quality are specified below.
7.2.2.2 Grease Quality / Grease Change
The bearings are packed with high-quality lithium-soap grease.

Under normal conditions grease-lubricated rolling element
bearings will run for 25,000 operating hours or for 2 years.
Under unfavourable operating conditions, e.g. high room
temperature, high atmospheric humidity, dust-laden air,
aggressive industrial atmosphere etc., the bearings should be
checked earlier and cleaned and re-lubricated, if required.
Use a lithium-soap grease, free of resin and acid, not liable to
crumble and with good rust-preventive characteristics. The
grease should have a penetration number between 2 and 3,
corresponding to a worked penetration between 220 and
295 mm/10. Its drop point must not be below 175 C. The
bearing cavities must only be half-filled with grease.
If required, the bearings may be lubricated with greases of other
soap bases. Since greases of differing soap bases must not be
mixed, the bearings must be thoroughly cleaned beforehand.
The re-lubrication intervals required must then be adjusted to
the greases used.
Caution
Please observe the local laws applicable to the disposal of such
substances!
7.2.2.3 Deep-groove Ball Bearings / Lubricant

Quantity
-- for KSB IEC motor
Deep-groove ball bearings to DIN 625
Code
Grease g
6004 C3
2
6205 C3
3
6206 C3
4
6208 C3
6
6209 C3
7
6210 C3
7
6212 C3
7
6213 C3
11
7.3
Drainage/Disposal
If the pump was used for handling liquids posing
health hazards, see to it that there is no risk to persons
or the environment when draining the medium. All
relevant laws must be heeded. If required, wear
safety clothing and a protective mask.
The flushing liquid used and any liquid residues in the pump
must be properly collected and disposed of without posing any
risk to persons or the environment.
7.4
Dismantling
Before dismantling, secure the unit so as to make
sure it cannot be switched on accidentally.
The shut-off valves in the inlet/suction and discharge lines must

be closed.
The pump must have cooled down to ambient temperature, it
must have been drained and its pressure must be released.
7.4.1
Fundamental Instructions and

Recommendations
Repair and maintenance work to the pump must only be carried

out by specially trained personnel, using original spare parts
(see 2.7).
Observe the safety regulations laid down in section 7.1.
Any work on the motor shall be governed by the
specifications and regulations of the respective motor
supplier.
Dismantling and reassembly must always be carried out in
the sequence shown in the relevant exploded views on
pages 18 and 19.
In case of damage please contact our nearest customer service
centre.
For customer service centres please refer to the attached list
of addresses.
7.4.2
Preparations for Dismantling
7.4.3
Pump
1
2
2.1
2.2
Interrupt power supply.

Dismantling the complete unit:
Disconnect the motor.
Disconnect the discharge and suction nozzle from the
piping.
2.3 Depending on the pump/motor size, unscrew the bolts
that fix the support foot to the foundation.
2.4 Remove the complete unit from the piping.
3
The pump casing remains in the piping during dismantling.
3.1 Disconnect the motor.
3.2 Unscrew hex. nuts 920.1 and 920.2.
3.3 Withdraw the complete rotating assembly with the motor
from the pump casing.
4
Pump remains in the piping, motor is removed
4.1 Disconnect the motor.
4.2 Remove screws on cover plates 68-3, press cover plates
slightly together and remove from the drive lantern 341.
4.3 Undo hex. nuts 920.4.
4.4 Undo socket head cap screws 914.1.
4.5 Undo hex. head bolts 901.1.
4.6 Insert both lockwashers 931 into the keyway in shaft 210.
4.7 Tighten hex. head bolts 901.1.
4.8 Remove the motor.
After a prolonged period of operation the individual components may be hard to pull off the shaft. If this is the case, use
a brand name penetrating agent and/or -- if possible -- an appropriate pull-off device.
Under no circumstances use force.
Dismantle the pump in the sequence shown in the exploded

views on pages 18 and 19.
11
Etaline
7.4.4
Mechanical Seal
7.5
7.5.1
Reassembly
Pump
In order to replace the mechanical seal the pump must be

dismantled.
After removing the impeller 230 pull the mechanical seal 433 off
the shaft by hand.
Prior to reassembly, clean the shaft sleeve 523 and touch up
score marks or scratches, if any, with a polishing cloth. If the
score marks are still visible, fit a new shaft sleeve. Clean the
seat ring location.
The pump should be reassembled in accordance with the rules

of sound engineering practice.
The locating surfaces of the individual components should be
coated with graphite or similar before reassembly. The same
applies to screwed connections.
O-rings should be should be examined for signs of damage and
replaced by new ones, if necessary.
Gaskets should always be replaced by new ones. Make sure
that new gaskets have the same thickness as the old ones.
Gaskets of asbestos-free materials or graphite must always be
fitted without using lubricants.
Avoid the use of mounting aids as far as possible. Should a
mounting aid be required after all, use a commercially available
contact adhesive (e.g. Pattex) or sealing agent (HYLOMAR or
Epple 33). The adhesive should only be applied at selected
points and in thin layers. Do not use cyanoacrylate
adhesives (quick-setting adhesives).
If the seal area between the impeller neck and the casing wear
ring is worn, the casing wear rings 502.1 and 502.2 (if fitted)
must be replaced by new ones.
Clearances:
Etaline GN, MN:
New 0.3 mm in diameter
Max. permissible enlargement to 0.9 mm in diameter
Reassembly is effected in reverse order to dismantling. Make
sure to assemble the components in their correct sequence.
7.5.2
7.5.3
Motor for Etaline GN, MN
The motor is reassembled in reverse order to dismantling.

Prior to commissioning make sure that the lockwashers 931 are
withdrawn from the shaft keyway and fixed with hex. head bolts
901.1.
Fig. 6
Lockwasher
Part No.
210
515
901.1
914.1
931
Part designation
Shaft
Taper lock ring
Hexagon head bolt
Socket head cap screw
Lockwasher
Caution
When mounting the shaft 210 onto the motor shaft butt the
motor shafts keyway and the slot of shaft 210 must be arranged
in line with each other and opposite the slot of taper lock ring
515.
Section A -- A
Mechanical Seal
Reassembly is effected in reverse order to dismantling.

The following rules must be observed when mounting the
mechanical seal:
Extreme care and cleanliness.
Prior to reassembly, clean the shaft sleeve 523 and touch up
grooves or scratches, if any, with a polishing cloth. If the score
marks are still visible, fit a new shaft sleeve.
The protecting wrapping of the contact faces should only be
removed immediately before assembly takes place.
Take care not to damage the seal faces and O-rings.
When mounting the seal, the shaft sleeve 523 may be
wetted with water to reduce the friction forces.
Caution
Epoxy rubber elastomers must never come into contact
with oil or grease. Water should be used as a lubricant
during fitting.
12
901.1
Fig. 7
Shaft assembly
Etaline
7.6
7.6.1
Spare Parts Stock

Interchangeability of Etaline and Etabloc Components and Interchangeability of Components
among Each Other
502.2
Shaft sleeve
Casing wear ring,

suction side
Casing wear ring,
discharge side
502.1
Mechanical seal
433
32-160.1/...
32-200/... 25
12
32-200.1/...
40-160/... 25
32-160/...
40-250/... 25
32-250/...
50-160/... 25
40-160/...
50-250/... 25
40-250/...
65-160/... 25
50-160/...
65-250/... 25
16
50-250/...
80-160/... 25
11
65-160/...
80-210/... 25
16
65-200/...
Motor
71
80
90
100/
112
132
160
180
200
225
523
102
32-160/... 25
Etaline 1)
163
Shaft unit
210
Part No.
Impeller
Shaft (with taper lock ring)
230
Discharge cover
Volute casing
Part designation
250
Etabloc
80-250/... 35
65-250/...
100-125/... 25
10
65-125/...
100-160/... 25
65-160/...
100-170/... 25
80-160/...
100-200/... 35
80-200/...
100-250/... 35
10
80-250/...
125-160/... 35
11
100-160/...
125-200/... 35
12
17
100-200/...
125-250/... 35
10
100-250/...
150-200/... 35
10
125-200/...
150-250/... 35
10
11
125-250/...
200-250/... 35
13
10
11
12
150-250/...
200-315/... 55
14
13
14
15
150-315/...
Motor Power rating
1
1
Same number means same component
Components differ
When other frequencies or power reserves are required for this pump/motor combination, consult KSB.
This pump/motor combination is not possible

Components are interchangeable with Etabloc
1)
The pump components of Etaline single pump units and twin pump
units are identical, except for the volute casing.
71
.../024, .../034
80
.../054, .../074, .../072, .../112
90
.../114, .../154, .../152, .../222
100
.../224, .../304, .../302
112
.../404, .../402
132
.../554, .../754, .../552, .../752
160
.../1104, .../1504, .../1102, .../1502, .../1852
180
.../1854, .../2204, .../2202
200
.../3004, .../3002, .../3702
225
.../3704, .../4504, .../4502
250
.../5504
13
Etaline
7.6.2
Ordering Spare Parts
When ordering spare parts please always quote the following

data stated on the name plate, for example:
Name plate specimen
D-67227 Frankenthal
Type series and size
ETALINE-GN 65-160/752.2
Design and Ident No..
GN 6
Order No.
0005130825
48 859 104
003000 01
m3/h
Capacity and head
Q 13,5 -- 90,0
Speed and serial No.
n = 2900 1/min
H 33 -- 20 m
Jahr 2006
The following data are required as well:

part designation, part number, quantity of spare parts, address
and mode of dispatch (freight, mail, express freight, airfreight).
7.6.3
Part No.
Recommended Spare Parts Stock for 2 Years Continuous Operation in Accordance with VDMA 24 296
Part designation
Number of pumps (including stand-by pumps)

2
6 and 7
8 and 9
10 and more
Quantity of spare parts

210
Shaft complete, consisting of

Shaft 210
Disc 550 1)
Socket head cap screw 914.1
Hexagon nut 920.5
Safety device 930
Key 940
Taper lock ring 515
30 %
230
Impeller (including casing wear ring 502.2) 2)
30 %
400.1
Gasket
12
150 %
433
Mechanical seal, complete
90 %
502.1
Casing wear ring
50 %
523
Shaft sleeve (incl. gasket 400.2)
50 %
1)
2)
14
Only for Etaline with shaft unit 25

Not for Etaline 40-125/..., 50-125/..., 65-125/...
Etaline
Excessive rise of temperature inside the pump
Vibrations during pump operation
Excessive leakage at the shaft seal
Leakage at the pump
Motor protection switch/thermistor trip device trips the unit

Increase in bearing temperature
Trouble-shooting
Drive is overloaded
Pump delivers insufficient flow rate
Cause
Remedy 1)
Pump delivers against an excessively high discharge

pressure.
Re-adjust duty point.
Excessively high back pressure.
Check plant for impurities.
D D Pump or piping are not completely vented or primed.
Vent and/or prime.
Supply line or impeller clogged.
Remove deposits in the pump and/or piping.
Formation of air pockets in the piping.
Alter piping layout.

Fit a vent valve.
D D Suction head is too high/NPSH available (positive suction

head) is too low.
Reverse rotation.
Interchange two of the phases of the power supply cable.
Worn internal parts.
Replace worn components by new ones.
Pump back pressure is lower than specified in the purchase order.
Adjust duty point accurately.
Density or viscosity of the fluid pumped is higher than

stated in the purchase order.
2)
D
D
D D
D
Defective seal element.
Fit new seal between volute casing and discharge cover.
Worn shaft seal.
Fit new shaft seal.
Score marks or roughness on shaft sleeve.
Fit new shaft sleeve.

Fit new shaft seal.
Vibrations during pump operation.
Improve suction conditions.

Increase the pressure at the pump suction nozzle.
D D
Pump is warped.
Check pipeline connections and secure fixing of pump; if

required, reduce the distances between the pipe clamps.
Fix the pipelines using anti-vibration material.
Increased axial thrust. 2)
Clean balancing holes in the impeller. Fit new wear rings.
Insufficient or excessive quantity of lubricant or unsuitable lubricant.
Top up, reduce or change lubricant.
Motor is running on two phases only.
Replace the defective fuse.

Check the electric cable connections.
Check the motor winding
Rotor is out of balance.
Clean the impeller.

Re-balance the impeller.
Defective bearings.
Fit new bearings.
D
D
D
D
D D
D D Insufficient rate of flow.

D
D D
Increase system pressure.

Check/alter liquid level.
Fully open shut-off valve in the suction head line.
Change suction head line, if the friction losses in the suction head line are too high.
Increase the minimum rate of flow.
Incorrect adjustment of motor protection switch.
Check setting.
Fit new motor protection switch.
Transport safety device has not been removed from the

shaft groove.
Remove.
1)
The pump pressure must be released before attempting to remedy

faults on parts which are subjected to pressure.
2) Please contact KSB.
15
Etaline
9
9.1
Relevant Documentation
Typical Installation Positions
5B
Fig. 8
Horizontal installation, direction of flow from bottom

to top
Fig. 9
Horizontal installation, direction of flow from top to

bottom. The pump casing must be turned by 180,
so that the condensation water holes point downwards and the terminal box remains in its position on
top.
Fig. 10
Vertical installation
If the pump set is installed vertically, the pump must
be vented through vent valve B5 (special design) so
as to avoid dry running of the mechanical seal.
Fig. 11
Horizontal installation (for ex. under the ceiling)
Duplex pumps must not be arranged in flow direction from top to bottom, since under certain operating conditions the changeover flap will not shut off
completely, which might produce reverse flow in the
second pump. In this case, changeover from the first
to the second pump might cause damage.
16
Etaline
To be
supported
Blind flange (accessory)
The motors of Etaline units with motors from size 180

and horizontal axis must be supported without transmitting any stresses or strains.
To this end, use the foot fixing holes on the motor housing.
Etaline fixed without feet
Etaline pump sizes

32-160/... to 100-160/...
fixed with three feet
Etaline pump sizes

100-170/...to 200-315/...
fixed with a pump foot
made of EN-GJL
If flexible pipe unions (expansion joints) are used or if the pump

set is installed with a pump foot, Etaline pumps must be fixed.
Appropriate fixing elements are available as pump accessories.
When dismantling the motor the volute casing may remain in
the piping.
17
Etaline
9.2
Exploded View and List of Components
Etaline GN
Variant with bolted-on discharge cover
Etaline GN
32-200/...
40-250/...
50-250/...
65-250/...
80-210/...
80-250/...
Etaline GN
100-250/...
125-250/...
150-250/...
200-250/...
( )
Not available as individual spare part
Part No.
102
163
182
210
230
341
400.1/.2
433
502.1/.2
515
523
550.1/.2
68-3
741
801
18
Part designation
Volute casing
Discharge cover
Foot
Shaft
Impeller
Drive lantern
Gasket
Mechanical seal
Casing wear ring
Taper lock ring
Shaft sleeve
Disc 1)
Cover plate
Vent valve
Flanged motor
[ ]
Supplied in packaging units only
Part No.
901.1
902.1-.4
903
914.1
920.2-.5
930
931
940
Part designation
Hexagon head bolt
Stud
Screwed plug
Hexagon nut
Safety device
Lockwasher
Key
Auxiliary connections:
1 M.1/.2
Pressure gauge
5B
Vent, mechanical seal chamber
6 B.1/.3
Pumped medium drain
6 D.1
Priming with pumped medium and venting
1)
Etaline
Etaline GN
Variant with clamped discharge cover
Etaline GN
32-160/...
40-160/...
50-160/...
65-160/...
80-160/...
100-125/...
100-160/...
Etaline GN
100-170/...
100-200/...
125-160/...
125-200/...
150-200/...
200-315/...
( )
Part No.
102
163
182
210
230
341
400.1/.2
433
502.1/.2
515
523
550.1
68-3
741
801
Part designation
Volute casing
Discharge cover
Foot
Shaft
Impeller
Drive lantern
Gasket
Mechanical seal
Casing wear ring
Taper lock ring
Shaft sleeve
Disc 1)
Cover plate
Vent valve
Flanged motor
[ ]
Part No.
901.1
902.2/.4
903
914.1
920.1/.3-.5
930
931
940
Part designation
Hexagon head bolt
Stud
Screwed plug
Hexagon nut
Safety device
Lockwasher
Key
Auxiliary connections:
1 M.1/.2
Pressure gauge
5B
Vent, mechanical seal chamber
6 B.1/.3
Pumped medium drain
6 D.1
Priming with pumped medium and venting
1)
19
Etaline
Sectional Drawing
Etaline GN with
bolted-on
discharge cover
32-200/...
40-250/...
50-250/...
65-250/...
80-210/...
80-250/...
100-250/...
125-250/...
150-250/...
200-250/...
Etaline GN with
clamped
discharge cover
32-160/...
40-160/...
50-160/...
65-160/...
80-160/...
100-125/...
100-160/...
100-170/...
100-200/...
125-160/...
125-200/...
150-200/...
200-315/...
( )
[ ]
1146.81/8-10 / 1.6.2007
Fixing impeller on shaft unit 35
Subject to technical modifications without prior notice.
01 044 056
9.3
Quick Start--Up Guide

4070.801--11
PumpDrive
Self-- Cooled,
Motor-- Independent
Frequency Converter
Mounting options:
Motor mounting (MM)
Wall mounting (WM)
Control cabinet mounting (CM)
Quick Start--Up Guide
PumpDrive
1 About this Guide
For detailed descriptions and instructions on how to properly use, maintain and
troubleshoot the pump, please refer to the operating manual of the
PumpDrive.
This guide
D is part of the PumpDrive
D helps you quickly put the PumpDrive into operation
D contains descriptions of the following subjects:
-- Location
-- Connecting cable
-- Installation
-- Start--up
-- Configuring the parameters
Warning labels and symbols
Symbol
Meaning
Safety warning sign
" Follow the instructions that appear next to the safety
warning sign to avoid injury or material damage.
Information, note
"
Instruction
Result
Risk of injury or material damage if unsafe work is done
CAUTION
" Observe the safety instructions (see operating instructions with the
number 4070.81, chapter 2, chapter 6.4.1).
" Keep the operating instructions constantly available at the location
of use.
PumpDrive
2 Location
The following requirements must be met:
D It must be well ventilated
D No exposure to direct sunlight or weather influences
D When installed outside it must protected against condensed water and sunlight
D Temperature range for pump operation: 0--40 C
D two separate copper rails must be provided to earth the pump (mains connection
rail and control connection rail)
3 Connecting cable
The following requirements must be met:
3.1 Power cable
D unshielded (shielding is optional)
D a motor circuit breaker that is capable of handling 1.4 x the nominal current
D maximum cable cross section, see Table1, on page 7
3.2 Control cable
D Shielded cable for the control cables, a minimum cross section of 0.5 mm2
D shielded cable for LON and Profibus
D between the control and power cables minimum clearance 0.3 m
3.3 Connecting cable between the PumpDrive and motor (with stray
capacitance Cs < 5 nF)
D to 7.5 kW class B, maximum cable length 5 m
D over 7.5 kW class A1, maximum cable length 50 m
D shielded
PumpDrive
4 Mounting the PumpDrive
Risk of injury or material damage if installed improperly
CAUTION
" Observe the safety instructions (see the operating manual,

chapter 2).
" To avoid starting the pump accidentally: Switch off the power and
lock to prevent power being reapplied.
In the installation option MM, the PumpDrive is already mounted on a standard

motor.
" For the installation options WM and CM: Mount the PumpDrive to the wall, to a rack
or into a control cabinet according to the enclosed installation instructions.
PumpDrive
5 Installation
Improper installation can cause material damage!
CAUTION
" Ensure that the power feed, motor connection wiring and control
wiring are all powered off and are protected from being powered up
again.
" Never remove the plastic housing from the metallic heat sink.
" Remove covers only as described in the guide.
" Make sure that earthing is provided meeting local and national
regulations.
5.1 Connection of motor and power wiring
Fig.1) Removing the V--shaped cover

" Unscrew the three cross head screws (1) on the V--shaped cover (1) for the mains
and motor connection and then remove the cover (see Fig.1).
" Connect the power or motor cable to the terminals in the connection compartment
on the PumpDrive (see Fig.2andFig.3). Use suitable cable connections (see
table 1, page 7).
Fig.2) Connection compartment for the power and motor cables

5
PumpDrive
1 terminal for the power connection 3 terminal for the motor connection
2 analogue input 2
4 terminal for control connection
Fig.3) Power and motor connections in the connection compartment of the PumpDrive
PumpDrive
Risk of injury or material damage if improperly earthed
CAUTION
" Do not connect the shielding of the connection cable to the earthing
rail in the control cabinet or to the control earthing rail.
" Provide the shielding of the connection cable in a single piece and
earth it on both ends.
" Connect the shielding of the control cables to the signal earth.
Size
PumpDrive
Power
[kW]
Cable glands for

Mains
supply
cable
Sensorcable
Motor
cable
PTC
therm
istor
Input
p
current1)
[A]
.. 000K55 ..
0,55
1,9
.. 000K75 ..
0,75
2,6
.. 001K10 ..
1,1
.. 001K50 ..
1,5
.. 002K20 ..
2,2
6,3
.. 003K00 ..
8,5
.. 004K00 ..
10,5
.. 005K50 ..
5,5
.. 007K50 ..
7,5
.. 011K00 ..
11
.. 015K00 ..
15
.. 018K50 ..
18,5
.. 022K00 ..
22
.. 030K00 ..
30
.. 037K00 ..
37
.. 045K00 ..
45
M25
M25
M16
M16
M25
M25
M16
M16
3,7
5
13,7
Max.
Cable
cross
section
[mm2]
25
2,5
2,5
17,3
26,5
M32
M16
M32
M16
32,6
41
10
47,3
68,3
M40
M16
M40
M16
84
35
97,7
1) Observe the notes on using line chokes (see the operating manual, section Accessories and options under
Line chokes!
Table1) Cable connections for power and motor connections
PumpDrive
5.2 Connecting the control wiring
" Unscrew the three cross head screws (1) on the L--shaped cover (2) for the
control cables and then remove the cover (see Fig.4).
Fig.4) Removing the L--shaped cover

Material damage due to improper removal of the
control unit
CAUTION
" When removing the control unit: Use a flat screwdriver at the top end
as a lever.
" Unscrew the cross head screws (1) on the control unit and then remove the
control unit (see Fig.5).
Fig.5) Removing the L--shaped cover

The terminal strips P4 and P7 are located under the control unit (see Fig.6).
PumpDrive
Fig.6) Position of the terminal strips P4 and P7 (1)
PumpDrive
6 Start--up
" Depending on the version and operating mode, choose a chapter from the table.
Operating mode
Version
without control unit
with control unit
Internal setpoint specification
Section 6.1, page 10
External setpoint specification
Internal setpoint specification
External setpoint specification
Actuated operation:
Regulated operation:
6.1 Without control unit -- actuator operation -- setpoint specification

internal/external
With the assistance of the PumpDrive PC software, PumpDrive can also be
configured without a control unit, as follows:
-- via the serial interface with a special connecting cable
(mini USB--RS232), connect a PC/Notebook
-- configure as with the control unit (see section 6.4, page 11)
" If the setpoint signal is only between 0 and 10 V: connect the setpoint signal to
terminal P7, analogue input 1
" Check the direction of rotation (see section 6.8, page 14).
6.2 Without control unit -- regulated operation -- setpoint specification
internal/external
With the assistance of the PumpDrive PC software, PumpDrive can also be
configured without a control unit, as follows:
-- via the serial interface with a special connecting cable
(mini USB--RS232), connect a PC/Notebook
-- configure as with the control unit (see section 6.6, page 13)
" For an actual signal between 4 and 20 mA: connect the actual signal to
terminal P7, analogue input 2.
10
PumpDrive
6.3 With control unit -- actuator operation -- setpoint specification internal
" Configure the source for the setpoint on the control unit:
-- Select parameter 3--5--4--1 and set menu point 4.
-- Select parameter 3--5--2--1 and set value between the lower and the upper
setpoint limits.
" If the lower and upper setpoints differ from the factory set 0 % and 100 %: Set
lower and upper setpoints:
-- Select parameter 3--5--1--2 and set the value.
-- Select parameter 3--5--1--3 and set the value.
" Select parameter 3--5--1--4 and set to AUTO.
6.4 With control unit -- actuator operation -- setpoint specification external
" If the setpoint signal does not lie between 0 and 10 V, or if more than one setpoint
should be used, see section Configure source for setpoint signal.
Set source for setpoint signal
A maximum of 3 sources can be set for setpoints
" Set sources for setpoints (see Table2 and section 6.9).
" If setpoint signal is not between 0 and 10 V:
-- Configure source for setpoint (see operating instructions, section 8.3, table 22).
-- If analogue input 1 is set as the source for setpoint: Configure analogue input 1
(see operating instructions, section 8.2, table 18).
11
PumpDrive
Parameter
Description
Setting options
3--5--4--1
Source for setpoint signal 1
1, 2, 3, 4, 5, 6
3--5--4--2
1, 2, 3, 4, 5, 6
3--5--4--3
1, 2, 3, 4, 5, 6
1 -- No source
2 -- Analogue input 1
4 -- Configurable setpoint
5 -- Fieldbus setpoint
6 -- RS232 -- setpoint
Table2) Source for setpoint

6.5 With control unit -- regulated operation -- setpoint specification internal
" Configure the source for the setpoint on the control unit:
-- Select parameter 3--5--4--1 (see section 6.9).
-- Set parameter to 4.
-- Select parameter 3--5--2--1 and set value between the lower and the upper
setpoint limits.
" If the actual signal does not lie between 4 and 20 mA: see section Configure
source for actual signal.
" Check the direction of rotation (see section 6.8).
Set source for actual signal
The actual signal can be read in from 7 different sources.
" Set sources for actual signals (see Table3 and section 6.9).
" If the actual signal does not lie between 4 and 20 mA: Configure source for actual
value (see operating instructions, section 8.3, table 26).
Parameter
Description
Setting options
3--9--2--1
Source for actual signal 1
1, 2, 3, 4, 5, 6
1
2
3
4
-----
Analogue input 1
Analogue input 2
DIFF (AI1, AI2)
MIN (AI1, AI2)
Table3) Sources for actual

12
5 -- MAX (AI1, AI2)

6 -- AVE (AI1, AI2)
7 -- Rem actual
PumpDrive
6.6 With control unit -- regulated operation -- setpoint specification external
" If the setpoint signal does not lie between 0 and 10 V, or if more than one setpoint
should be used, see section Configure source for setpoint signal.
" If the actual signal does not lie between 4 and 20 mA: see section Configure
source for actual signal.
" Check the direction of rotation (see section 6.8).
Set source for setpoint signal
A maximum of 3 sources can be set for setpoints.
" Set sources for setpoints (see Table4 and section 6.9).
" If setpoint signal is not between 0 and 10 V:
-- Configure source for setpoint (see operating instructions, section 8.3, table 22).
Parameter
Description
Setting options
3--5--4--1
Source for setpoint signal

1
1, 2, 3, 4, 5, 6
3--5--4--2

2
1, 2, 3, 4, 5, 6
3--5--4--3

3
1, 2, 3, 4, 5, 6
1 -- No source
4 -- Internal setpoint
5 -- Fieldbus setpoint
6 -- RS232 -- setpoint
Table4) Source for setpoint
13
PumpDrive
Set source for actual signal
The actual signal can be read in from 7 different sources.
" Set source for actual signal (see Table5 and section 6.9).
" If the actual signal does not lie between 4 and 20 mA: Configure source for actual
value (see operating instructions, section 8.3, table 26).
Parameter
Description
Setting options
3--9--2--1
Source for actual signal 1
1, 2, 3, 4, 5, 6
1
2
3
4
-----
Analogue input 1
Analogue input 2
DIFF (AI1, AI2)
MIN (AI1, AI2)
5 -- MAX (AI1, AI2)

6 -- AVE (AI1, AI2)
7 -- Rem actual
Table5) Sources for actual

6.7 Configuring motor data
" Call up the following parameters and set suitable values for the motor:
Parameter
Description
Setting options
3--3--2--1
Nominal power
0.55..110 [kW]
3--3--2--2
Nominal voltage
342..528 [V]
3--3--2--3
Nominal frequency
45..65 [Hz]
3--3--2--4
Nominal current
0.1..999 [A]
3--3--2--5
Nominal motor speed
300..3600 [rpm]
3--3--2--6
Nominal phase shift
Table6) Configuring motor data

6.8 Checking the direction of rotation
" If control unit available: Press the <Man> button on the control unit.
The drive will then be operated at a speed below the minimum limit value of the
motor frequency.
" If no control unit available: Connect 24 V to digital input 1.
" If direction of rotation incorrect: Swap two motor phases.
14
PumpDrive
6.9 Configuring the parameters
Fig.7) Front panel of control unit
Fig.8) Parameter 3--2--1--3 (example)
" Select the related four--digit parameter value from the table and enter it as follows
via the control unit (see Fig.7 and Fig.8):
-- Enter the first digit with the four yellow buttons on the control unit. The four
buttons represent the digits 1 to 4.
-- For all other digits press the <Up/Down> buttons on the control unit until the digit
of the parameter appears in the left top corner and then confirm by pressing
<OK>.
15
We reserve the right to make technical changes.

14.02.2006
4070.801--11
67225 Frankenthal Johann-Klein-Str. 9 67227 Frankenthal
(Germany)
Tel. +49 (0)6233 86-0 Fax +49 6233 86-3401 www.ksb.de
PumpDrive
13.3
Connection examples
13.3.1
Open-loop control mode
Fig. 39: Connection example for open-loop control mode

121
description
parameter setting and

adjustment for all pumps
Multitec 2-pol
2900 1/min
Rated power
Rated voltage
Rated frequency
Rated current
Rated speed
Rated cosphi
Resetting to factory settings
information resp. changing motor frequency <> 50 Hz

max. motor frequency
3-11-4-1
Max Out Freq
on demand:
3-1-5-5
Back Fac Settgs
motor identification plate
preset: 50 Hz
factory-made preset
84% = 42Hz
800 1/min
84% = 42Hz
800 1/min
Etanorm RSY 6-pol

960 1/min
56% = 28Hz
800 1/min
56% = 28Hz
800 1/min
Etaline SY 4-pol
1450 1/min
Presetting of frequency controller in case of

motor mounted frequency controller
"motor mounted" version not possible for Etaline SY, Etablock SY
56% = 28Hz
800 1/min
56% = 28Hz
800 1/min
Etanorm SYA 4-pol

1450 1/min
customer level
0000
change of language
english
change of KSB password
operating values in the main 1: power [kW]
menue
2: motor current [A]
3: operating hours counter [h]
4: energy meter [kWh]
manual operation
[Man] Key
locked
off
[Off] Key
locked
function
[Func] Key
Trip Reset
32% = 16Hz
Frequence lo
Min. frequence, refered to
900 1/min
3-11-4-1 Max Out Freq
if motor frequency (3-3-2-3) e.g. 60Hz, all percentage values for 3-6-1-2 must be adjusted refered to 3-11-4-1
Stop & Trip
Life Zero Fnc
sensor monitoring wire
break
set point signal
AI 1 Setting
current
adjusting range 4-20mA =
32% = 16Hz
AnIn1 Lo
Fmin to Fmax
900 1/min
Login
Language
Customer Passwd
User config
Saving of parameter settings:

Turning on and off frequency controller
Check:
3-3-2-1
3-3-2-2
3-3-2-3
3-3-2-4
3-3-2-5
3-3-2-6
3-8-2-1
3-8-2-7
attention:
3-8-1-2
3-1-4-1
3-1-4-2
3-1-4-3
3-6-1-2
3-1-6-1
3-1-1-1
3-1-6-4
3-1-3-1
adjust:
parameter
PumpDrive parameter settings company LOOS
35% = 17,5Hz
500 1/min
35% = 17,5Hz
500 1/min
56% =28Hz 84% = 42Hz

800 1/min
800 1/min
56% =28Hz 84% = 42Hz

800 1/min
800 1/min
Etaline GN 4-pol HPK-L 4-pol HPK-L 6-pol

1450 1/min
1450 1/min 960 1/min
Equipment for fuel supply

and heat recovery
VENTA Luft- u. Wrmetechnik GmbH

Postfach 40 01 89, D-74510 Schwbisch Hall
Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
High performance fans
For product line
Radial fans,
Axial fans
MHI, NHI, SgHI, HI, SI, UV, RFPK

A, AL

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
Table of Contents
1.
Order data ......................................................................................................... 3

1.1. Performance data ....................................................................................... 3
1.2. Motor data................................................................................................... 3
2.
Introduction ...................................................................................................... 3
3.
Safety ................................................................................................................ 3
3.1. Symbols ...................................................................................................... 3
3.2. General occupational safety references ..................................................... 3
3.3. Special occupational safety references ...................................................... 4
3.4. Warranty ..................................................................................................... 4
4.
Design and operation ...................................................................................... 5
5.
Transportation, delivery and storage ............................................................. 5

5.1. Transportation............................................................................................. 5
5.2. Delivery ....................................................................................................... 6
5.3. Storage ....................................................................................................... 6
6.
Installation ........................................................................................................ 7
6.1. Installation preparations.............................................................................. 7
6.2. Installing the fan.......................................................................................... 7
6.3. Air tube connections ................................................................................... 7
6.4. Impeller ....................................................................................................... 7
6.5. Anti-friction bearings ................................................................................... 8
6.6. V-belts......................................................................................................... 8
6.7. Electrical connection ................................................................................... 8
7.
Commissioning ................................................................................................ 9
7.1. Trouble-shooting during commissioning ................................................... 10
8.
Maintenance ................................................................................................... 11
8.1. Service notes ............................................................................................ 11
8.2. Maintenance and inspection list ................................................................ 12
8.3. Bearing grease addition and replacement ............................................. 13
8.4. Dealing with defects and corrective maintenance..................................... 14
9.
Spare Parts ..................................................................................................... 15

9.1. Maintaining spare parts............................................................................. 15
9.2. Ordering of spare parts ............................................................................. 15
9.3. Spare part and after-sales service address .............................................. 15
VENTA-BA-en.pdf

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
1.
VENTA
Order data
1.1. Performance data

The order and performance data can be found on the fans type/rating plate.
1.2. Motor data
The motor data is shown on the motors rating plate.
2.
Introduction
The Operating Instructions contain important notes for the safe, expert and economic
operation of the fan. Complying with them helps to avoid dangers and to reduce repair costs and downtimes and increases the reliability and durability of the fan. The
documentation contains additional details, which should also be observed. Should
you require more information with regard to the fan than those contained in these
Operating Instructions, please do not hesitate to contact the manufacturer. These
Operating Instructions are valid for all series and drive types. The technical execution
of the fans complies with DIN 24166 Technical Delivery Conditions for Fans.
3.
Safety
3.1. Symbols
- General danger reference

- Information / tip:
3.2. General occupational safety references

Each person in the operating authority's company dealing with the transport, installation, dismounting, putting into operation, operation and maintenance of the
fan must have read and understood the entire operating instructions. It is recommended that the operating authority have this fact confirmed in writing
each time.
Apart from the operating instructions and the regulations with regard to the prevention of accidents valid at the place of use, it is also necessary to comply with
the approved technical regulations for safe and professional work.
The fan has been manufactured according to state-of-the-art technology and
recognized safety regulations. Nevertheless it is possible for dangers to life
and limb of persons, or damages to or impairments of the facility and other
material assets to arise.
The fan may only be operated if it is in a perfect technical condition and if it is
used in accordance with the intended use and with the necessary awareness
of safety aspects and the dangers involved under consideration of the operating instructions. It is in particular necessary to repair failures impairing the
safety of the facility without delay.
VENTA-BA-en.pdf
Page 3

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
-
VENTA
The delivery scope supply is specified in the Order Confirmation. If additional

safety measures are required, these must be provided and installed by the
operator of the fan.
Installation, dismounting, operation, maintenance and corrective maintenance
of the fan may only be carried out by authorised and competent staff.
The Operating Instructions must be available at all times at the fan's place of
use. The manufacturer cannot be held liable for any damages resulting from
the unauthorised use of the fan or from non-compliance with the technical
documentation.
In explosive atmospheres, fans may only be used in accordance with Directive 94/9/EU (ATEX). The Supplementary information for explosionproof fans must be observed.
3.3. Special occupational safety references

Any work on the fan may only be carried out while the fan is standing still. It must
be ensured that the motor cannot be switched on unintentionally. This may e.g.
be achieved by means of a lockable repair switch (not contained in the delivery
scope).
The drive motor must be connected in accordance with the general electric regulations as well as with the manufacturer's connection specifications.
Freely accessible air intake and pressure joints must be safeguarded by adequate protection (e.g. wire trellis).
Before switching on the fan it is to be verified that all safety devices and cleaning
flaps have been properly installed.
After the relevant electric installation has been completed, the direction of rotation
and the protective measures employed have to be checked.
Hot gas fans with operating temperatures exceeding 100C may not be operated
at less than half the operating speed. When switching off the system, the fans
must continue to run until the temperature is lower than 100C.
The valid standards and regulations must be observed with regard to the approved surface temperatures. It may be necessary on the customer side to plan
on having design measures in place e.g. to insulate the housing or to mount
warning signs.
3.4. Warranty
The warranty period may be found in our Terms of Business. If requested, we would
be pleased to send you a copy of our Terms of Business. If any special agreements
have been reached apart from this, these have been specified in the Order Confirmation.
The warranty agreed upon can only be accepted if the following requirements have
been met:
Transportation has been done professionally
Expert installation, commissioning and operation in accordance with the operating instructions on hand.
Provable observance of the stipulated maintenance intervals.
Operation of the fan only in the permitted range with regard to speed, temperature, etc. (see rating plate on fan or Order Confirmation)
VENTA-BA-en.pdf
Page 4

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
-
4.
VENTA
Fan is operated using pumping media that has the chemical and physical
properties outlined in the Order Confirmation.
All damages are reported to the manufacturer immediately.
Only original spare parts are used.
The manufacturer must agree any structure modifications to the original state.
Design and operation
In the axial fan, the air is conveyed in the axial direction.

The radial fan is equipped with an impeller in which the incoming axial air is diverted
in a radial direction. Inside the impeller, the supplied energy is transformed into a
mass flow and an increase in the pressure.
The standard design of the fan consists of a motor console with the bolted-on drive
motor; the impeller is fastened on the shaft journal above the hub. Using an absolutely impervious shaft surround seals the place where the root exits the housing.
Depending on where and for which purpose the fan is being used, other designs
(e.g. with V-belt drive or coupling) and additional features (e.g. high quality shaft
seals, control organs, sound-proofing measures, vibration dampening subassemblies, electric monitoring, etc) are available.
5.
Transportation, delivery and storage
5.1. Transportation
A suitable means of transit in accordance with local situations and regulations must
be used for transportation.
The following must be observed:
- Accident prevention guidelines (issued in Germany by the German employers
liability insurance associations)
- Securing of the load in accordance with the Highway Code.
The fan must be lifted and transported using suitable load-bearing hoisting equipment (crane, forklift truck).
The fan may only be suspended by the fan housing or the basic frame on the transportation rack using the suspension shackles provided for this purpose. The shackles
on the motor are only designed for the weight of the motor itself.
During transportation, the fan must be secured against tipping over or shifting. The
responsible carrier, crane driver or forklift driver must check the load-bearing capabilities of the existing pallets or transit racks on site and they must be secured in that
position.
Setting the fan down hard or tilting it can result in damages to the fan.
No claims for replacement or warranty claims will be recognized because of inadequate means of transportation or improper methods of transportation.
VENTA-BA-en.pdf
Page 5

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
5.2. Delivery
The fans are predominantly supplied as pre-assembled units plus any loose accessory parts, which may have been ordered.
Please check whether the delivery is correct and complete using the delivery documents.
Report any complaints to the manufacturer without delay
5.3. Storage
These recommendations are value-retaining measures for periods during which the
fan is out of commission. The intervals and types of measurements must be ascertained by the owner/operator according to the storage conditions. The Operating Instructions from other manufacturers (motor, coupling, etc.) must also be observed.
5.3.1.
Storage location
The storage location should be dry, free from vibrations and dust-free. The relative
humidity should be lower than 60%. The recommended storage temperature equals
20 to +40C.
5.3.2.
-
If the unit is to be stored after extensive use exceeding 6 months, then the
bearing grease in the shaft bearing must be replaced prior to storage. The fan
should then be operated for a period of an hour, so that the grease can distribute evenly over the bearings.
Cover the suction and pressure joints in such a way that no foreign matter is
able to penetrate. It is necessary to ensure the interior of the housing is ventilated to prevent corrosion (e.g. open condensate drainage sleeve)
Unpainted metal surfaces may need to be conserved
Loosen belt
5.3.3.
Storage measures
Regular measures during downtimes
To avoid downtime corrosion, start up fan every 2 weeks for 5 minutes, or in

case of need turn impeller with some item (Caution: danger of accident).
5.3.4.
Re-commissioning
Observe the instructions in the Commissioning chapter during re-commissioning.

Special attention is required here with regard to storage-related damages (corrosion,
foreign matter, damaged bearings, damaged belts, etc.). Remove all the covers and
safety features and tighten the belt drive. The inspection cover may need to be resealed. All the threaded connections must be checked.
If stored for more than 1 year, the bearing grease in the motor and shaft bearing
must be replaced before re-commissioning (see motor manufacturers Operating Instructions).
If the storage time exceeds 3 years, the anti-friction bearings should be replaced before re-commissioning. In some brands of motors / types of motors, the motor bearings need to be replaced after downtimes of 3-4 years.
VENTA-BA-en.pdf
Page 6

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
6.
VENTA
Installation
As this chapter cannot address all the variations fully, please contact the manufacturer if you have any queries. This chapter refers to the initial installation of the fan
and the installation of subassemblies as part of any maintenance or replacement
work. The entire Operating Manual must be observed here.
6.1. Installation preparations
The foundation or the machine anchoring point must be flat and stable. No forces
may be transferred onto the fan by system parts (vibrations, heat expansions, etc.).
The transit locks must be removed shortly before installation. Transit locks can be
threaded bars on compensators, rigid connections on the plane of the vibration
dampers, etc.
6.2. Installing the fan
Please comply with the accident prevention regulations!
The fan may only be operated if all the parts are mounted in accordance
with the regulations. The safety measures and installation regulations
must be observed, especially if individually supplied parts are to be installed by the customer (e.g. loose inlet nozzles, fans on equipment to
protect against accidental contact on the customer side, etc.).
The transport cable may not be fastened onto the impeller, the motor
shaft or the motor under any circumstances.
Please observe the supplementary page entitled Supplementary instructions for explosion-proof fans (Ergnzende Hinweise fr explosionsgeschtzte Ventilatoren).
6.3. Air tube connections

In the case of flanged joints, screws are to be tightened alternatively and in
several steps.
Air tubing running to the suction and pressure joints must be perfectly straight
and the connections must not be mismatched (offset)
It may be necessary to install spoilers to avoid damages and pressure losses
on the compensators.
6.4. Impeller
The impeller must move freely at all times and may not bump into anything!
The inlet nozzles delivered separately (uninstalled) must be aligned exactly.
The impeller and the impeller hub are balanced as one unit. After loosening the connection, it is necessary to re-balance the hub again.
To dismantle the impeller, please contact the manufacturer.
VENTA-BA-en.pdf
Page 7

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
6.5. Anti-friction bearings

Work on the bearings may only be carried out by experienced technicians,
as there is a danger of accidents and a danger of damaging the fan, depending on the design type and the installation site.
The shaft and the bearings can be removed after the opening the bearing case. Here
it is necessary to observe that the subassemblies must be reinstalled in the reverse
order to that of dismantling the subassemblies in the same position. All the subassemblies must be cleaned carefully; during this procedure, examine subassemblies
for wear and replace subassemblies, if required. Anti-friction bearings may need to
be mounted or pulled off warm. Commonly available extractors must be used for this.
The recommended warm-up temperature is 80C.
6.6. V-belts
Placing a ruler over the face end of both pulleys controls the alignment of the pulleys.
The pulleys must be exactly on one plane and the axes must be situated parallel to
one another. The v-belts must be loose when they are not tensioned and must be
fitted onto the pulleys without using any force. The recommended setting force F is
shown on the plate and is measured as shown in Fig 1.
E... Deflection in millimetres

F... Setting force in Newton
Fig 1:
For this, e.g. a belt pre-tension measuring device is placed in the middle of the distance between the axis centres at right angles on a belt. By exerting pressure on the
measuring device, the belt is deflected to measurement E on the deflection scale;
the force F used for this is then shown on the measuring device. The second belt or
a ruler, in the case of single belt drives, acts as a straight reference line. New belts
must be set to a force F that is 1.25 times higher (than what is shown on the plate).
6.7. Electrical connection
When connecting the electric motor, the following points must be taken into consideration:
The respective valid national electric regulations.
All connection work may only be carried out by an authorised specialist and in
accordance with the motor manufacturer's instructions.
The available supply voltage and frequency must correspond with the data
specified on the motor rating plate.
The circuit diagrams inside the motor terminal box must be observed.
VENTA-BA-en.pdf
Page 8

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
-
VENTA
The power supply cable must be protected against damages and dimensioned
in accordance with the power consumption.
The protective devices (protective motor relay, earthing resistor, etc.) must be
connected, checked and adjusted/set.
The cooling air supply for the motor must not be obstructed.
The earthing must be performed in accordance with the national regulations
and the regulations of the local energy supply company.
High-voltage! The connection may only be carried out while the network
is voltage-free!
Check for the impellers correct rotating direction using brief activation and compare
this with the rotating direction arrow on the fan housing (or on the motor). In case of
an incorrect direction of rotation, the drive motor may become overloaded!
If the commissioning is not done immediately after the installation, then the fan must
be secured against unauthorized use.
7.
Commissioning
The following points must be checked prior to commissioning:

Foundation anchors
Smooth running of the impeller
Inlet nozzle must be aligned exactly to the impeller
Foreign matter must be removed from the fan housing and any supply lines
Threaded connections must fit firmly
Air tube connections
Pulley alignment
V-belt tension
Coupling alignment
Please observe the following points during commissioning:
When the fan is switched on for the first time, the throttle in the facility system
should be closed, as otherwise the motor could overload. After the fan has run
up, the throttle must be opened slowly until the desired operating point has
been reached. The motors power consumption must not exceed the nominal
current at the operating speed.
The maximum operating speed may not be exceeded.
The fans vibration response must be checked. The valid standards and regulations must be observed with regard to this.
In the case of belt-driven fans, switch off the motor after a few hours of initial
operation under operating conditions, check belt tension and correct if necessary.
We recommend preparing a Commissioning Report.
VENTA-BA-en.pdf
Page 9

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
7.1. Trouble-shooting during commissioning

Malfunction
Possible cause
Possible remedy
- The motor switches - Existing

switchgears - Adjust switchgears accordoff before reaching
have been incorrectly ingly, possibly provide for
the operating speed
adjusted or are not heavy run up
suitable
- The motor's power - The motor's direction of - Changing the direction of
consumption is excesrotation is incorrect
rotation by exchanging 2
sive
phases
- The system's resis- - Close available throttle until
tances are too low
the desired quantity of air
has been reached
- Excessive
rotating - Correct rotating speed
speed
- The desired air vol- - The motor's direction of - Changing the direction of
ume is not reached
rotation is incorrect
rotation by exchanging 2
phases
- A throttle is closed too - Open throttle accordingly
far
- The effective vibra- - Fan was warped while - Check screwed connections
tion speed is too high
being installed
- The impeller is unbal- - Check impeller, possibly
have it rebalanced by an
anced
expert
- Grinding noise in fan - Impeller rubs against - Check fan for warping and
the intake nozzle or on transit damages
the housing
- Check position of motor /
bearing as well as threaded
connections
- Check hub fit
- Motor noises
- Check motor for bearing
damages, replace bearing if
necessary
- Fan runs erratically
- Coupling halves are not - Check alignment according
in true alignment
to Manual
- V-belt pretension too - Check pre-tension and adlow
just tension
- Pulley out of balance
- Balance pulley
- Pulleys are not in true - Align pulleys
alignment
VENTA-BA-en.pdf
Page 10

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
8.
VENTA
Maintenance
The operating safety and service life depends considerably on proper maintenance.
Failures caused by insufficient or improper maintenance may give rise to high repair
costs and long downtimes. Thus, regular maintenance is imperative.
Please comply with the accident prevention regulations! Especially the

following:
Switch off machines and secure against re-starting
Wait until impeller is stationary
Surface temperature of subassemblies
Hazardous or dangerous substances
8.1. Service notes

The service intervals are dependent on the operating conditions and are defined by the owner/operator of the equipment; the owner/operator is responsible for this.
The fan is to be inspected optically and acoustically on a regular basis while it
is in an operating state. In case of any changes compared to the normal state,
the cause must be determined without delay and eliminated accordingly.
Provided protective and safety devices must be inspected on a regular basis
and, if necessary, must be repaired while the fan is switched off.
Threaded connections must be controlled at regular intervals and may need to
be retightened.
Regular examination of the belt tension (e.g. using a hand-held measuring
device) guarantees a long service life for the belts. New v-belts should be
checked frequently during the run-in phase.
Observe the instructions in the Commissioning chapter during recommissioning.
Balancing errors can appear as a result of encrustations or wear on the

impeller; these can damage the fan. We therefore recommend the vibrations be monitored under corresponding operating conditions.
VENTA-BA-en.pdf
Page 11

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
8.2. Maintenance and inspection list

This list is considered to be recommendation for normal operation
Maintenance and in- Maintenance and inspection work
spection intervals
24 hours after com- - Check air-tightness of housing
missioning
- Check smoothness of running
- Check temperature of bearing
- Re-tighten screws
Monthly
- Check smoothness of running (bearing noises and vibrations)
- Check bearing temperature (for belt and clutch drives)
- Perform visual examination of shaft seal or shaft surround
Annually
- Check air-tightness of housing; check housing for tension
cracks
- Re-tighten screws
- Check impeller for deformations, tension cracks and wear
- Clean fan (more frequently, depending on operating conditions)
- Open bearing case and replace bearing grease. (Depending on operating conditions, maybe after 2 years)
- Examine belt drive, coupling and all other wearing parts
for wear and tear
After re-greasing the bearing, see Chapter entitled Bearing grease
addition and replacement.
If the fan is equipped with accessories and externally supplied parts,
then it is necessary to comply with the operating and maintenance instructions in the appendix!
Maintenance and inspection work should be recorded in a certificate and
should be documented showing the name of the person instructed to
carry out this work and the date.
VENTA-BA-en.pdf
Page 12

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
8.3. Bearing grease addition and replacement

Please pay attention to the instructions in the Maintenance Chapter.
Use grease-resistant protective gloves when lubricating danger of allergic skin reactions!
The amount of grease to be used for re-lubricating, the grease type and
the lubrication intervals can be found on the plate on the motor or on the
fan.
In re-greasable bearings, the grease is usually applied on the housing using a grease
gun and a grease nipple. To effectively suppress the grease being used, the machine must be running. Excessive pressure should be avoided with the grease gun,
as otherwise the seals can be damaged. The shaft bearings must be lubricated using
lithium-soap grease.
8.3.1.
Adding grease in the motor bearing
Re-lubrication equipment is generally considered a custom accessory. Please observe the Operating Instructions from the motor manufacturer.
8.3.2.
Adding grease in the shaft bearing
With lubrication periods of more than 6 months, the whole grease quantity in the
bearings must be renewed after the lubrication period has expired.
8.3.3.
Replacing grease in the shaft bearing
The interval for replacing the grease can be found in the chapter Maintenance and
inspection list. The bearing case must be opened while the fan is stationary to renew the grease. The old grease must be replaced and the bearing must be filled
with fresh grease (see plate for grease quantity for initial filling). Pay attention to
cleanliness, so that no contaminants can get into the bearing case.
Caution: Danger of accident - See Chapter entitled Assembly Anti-friction

bearings
VENTA-BA-en.pdf
Page 13

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
VENTA
8.4. Dealing with defects and corrective maintenance

If a malfunction does occur, you should run through the following checklist. Should a
malfunction occur which has not been taken into account in this list, please contact
manufacturer directly.
Malfunction
Possible cause
Fan runs erratic- - Impeller is unbalanced due

ally
to following:
- Encrustations
- Material
decomposition,
e.g. because of aggressive
pumping media
- Deformation
- Wear
- Wear on flexible elements
- V-belt pretension too low
Temperature rise - Increased flexing work innear bearing
side the bearing due to recent re-lubrication, and/or
replace bearings
- Greasing intervals were not
observed
- Bearings
were
warped
while being installed
- Excessive heat transfer in
the case of fans with hot
conveying media
Leak at the shaft - Sealing element worn
exit
Possible remedy
- Carefully remove encrustations, re-balance if necessary
- Consult manufacturer, replace
impeller, check bearing, if
necessary
- Replace flexible elements
- Check pre-tension and retighten, replace v-belt, if necessary
- Continue to operate fan, after a
certain time temperature will return to normal by itself
- Re-lubricate and replace bearing if necessary
- Correct bearing installation and
replace bearing if necessary
- Decrease temperature of pumping media; replace bearing if
bearing is already damaged
- Exchange sealing element
Grinding noise in - Impeller grinds against inlet - Check fan for warping and
fan
nozzle
check for transit damages
- Check position of motor / bearing as well as threaded connections
- Check hub fit
- Motor noises
- Check motor for bearing damages, replace bearing if necessary
VENTA-BA-en.pdf
Page 14

Tel.: +49 (0)791 / 93034-0
Fax: +49 (0)791 / 93034-24
9.
VENTA
Spare Parts
9.1. Maintaining spare parts

In order to keep the fan ready for operation and available at all times, it is necessary
to keep a stock of the most important spares and wearing parts. Respective spare
parts can be found in the Spare Part Lists.
The use of non-original spare parts can have a detrimental effect on the
fan's properties and may impair safety. We would like to point out again
that the warranty is only valid as long as original spare parts are used
exclusively.
9.2. Ordering of spare parts
When ordering spare parts, please always specify the following data:
Order number of supplied fan
Serial number of supplied fan
Item number of spare part in Spare Parts List
Description of spare part
Desired quantity
9.3. Spare part and after-sales service address
Please contact the following address:
VENTA Luft- und Wrmetechnik GmbH
Postfach 40 01 89
D-74510 Schwbisch Hall-Hessental
Telephone: +49 (0)791 / 93034 - 0
Telefax:
+49 (0)791 / 93034 - 24
Email
technik@venta-luw.de
verkauf@venta-luw.de
Internet:
http://venta-luw.de
VENTA-BA-en.pdf
Page 15
Drehstrommotoren
1LG4
1LG6
1LG9
1LP4
1PP4
1LP6
1PP6
1LP9
1PP9
Moteurs triphass
Motores trifsicos
Motori trifasi
Trefasmotorer
Tfzov motory

Betriebsanleitung / Instructions
Alle Rechte vorbehalten. All rights reserved. Tous droits rservs.

Reservados todos los derechos. Tutti i diritti riservati. All rtt frbehlles.
Veker prva vyhrazena. .
Ausgabe / Edition N14-0105
Bestell-Nr./Order No.: 35037000000057
DEUTSCH/ENGLISH/FRANCAIS/ESPANNOL/ITALIANO/SVENSKA/ESKY/
BG 180M ... 315L
Baugren (BG)
Frame sizes (BG)
Dsignation de carcasse (BG)
Tamaos constuctivos (BG)
Grandezze (BG)
Storlekar (BG)
Konstrukn velikosti (BG)
(BG)
Bauformen / Types of construction / Formes de construction / Formas constructivas / Forme costruttive / Monteringsstt / Konstrukn tvary /
(1ME6)
(1ME6)
oder
or
ou
o
oppure
eller
nebo
IM B 3
IM V 5
oder
or
ou
o
oppure
eller
nebo
IM V 6
IM B 5
IM B 6
IM B 7
IM V 1
IM V 3
IM B 35
IM B 34
IM B 8
Fig. 1
DEUTSCH
Allgemeine Hinweise
1.1
Zu beachten sind die Angaben und

Anweisungen in allen gelieferten Betriebs- und sonstigen Anleitungen.
Dies ist zur Vermeidung von Gefahren und Schden unerllich!
WARNUNG
Meflchenschalldruckpegel bei 50Hz (DIN EN 21 680 Teil 1)

1LG4, 1LG6, 1LG9,
ca. 60 bis 76 dB(A)
Weiterhin sind die jeweils geltenden nationalen, rtlichen und

anlagespezifischen Bestimmungen und Erfordernisse zu
bercksichtigen!
1.2
Aufbau und Arbeitsweise
1LG4-, 1LG6- und 1LG9- Motoren sind in Grundausfhrung eigengekhlt mit Lfter. Wahlweise knnen 1LG.-Motoren zudem
ohne Eigenlfter (z.B. als Lftermotoren mit Khlung durch einen
auf dem Wellenende angeordneten Sonderlfter) oder fremdbelftet
(Option G17) ausgefhrt werden. 1PP4, 1PP6, und 1PP9-Motoren
sind selbstgekhlt ohne Lfter.
Sonderausfhrungen und Bauvarianten knnen in technischen Details abweichen! Bei eventuellen Unklarheiten wird
dringend empfohlen, unter Angabe von Typbezeichnung und
Fabriknummer beim Hersteller rckzufragen, oder die Instandhaltungsarbeiten von einem der SIEMENS - Servicezentren
durchfhrenzulassen.
Bei Fumotoren sind die Fe am Motorgehuse angegossen,

wahlweise knnen angeschraubte Fe geliefert werden.(Option
K11 / s. Fig. 2).
HINWEIS: Fig. 2 ... (Ersatzteile) s. Anhang auf Seite 29
Siemens AG
Anwendungsbereich
Die Motoren knnen in staubiger oder feuchter Umgebung aufgestellt werden. Die Isolierung ist tropenfest. Bei sachgemer
Lagerung oder sachgemer Aufstellung im Freien sind normalerweise gegen Witterungseinflsse keine besonderen Schutzmanahmen an den Motoren notwendig.
Eine zustzliche Sicherheitsinformation (gelb) liegt bei, die

ergnzende Angaben zur Sicherheit fr elektrische Maschinen
enthlt. Diese Sicherheitsinformation ist deshalb eine Ergnzung fr alle weiteren noch gelieferten Betriebs- und sonstigen
Anleitungen.

Siemens AG 2000 All Rights Reserved
Beschreibung
Ein Umsetzen der Fe am Motorgehuse, z. B. zwecks

Vernderung der Klemmenkastenlage, ist bei den Optionen K09,
Bestell-Nr. / Order No. 35037000000057
-1-
DEUTSCH
Ggf. ist eine Nachwuchtung vorzunehmen, z. B. ist der aus dem
Abtriebselement und ber der Wellenkontur herausragende Teil
der Pafeder TP abzuarbeiten.
K10 und K11 mglich. Die dafr notwendigen Bohrungen und

Flchen sind bereits entsprechend bearbeitet.
Bei Motoren mit Bremse (z.B. Option G26) ist zustzlich die Bremsenbetriebsanleitung mit zu beachten!
Diese Hinweise gelten ergnzend zur Betriebsanleitung des
entsprechenden Motortyps. Sie gelten nicht fr Motoren in EEx e
Ausfhrungen.
Betrieb
WARNUNG
2.1
WARNUNG
Zu beachten sind die allgemein erforderlichen Manahmen fr den

Berhrungsschutz der Abtriebselemente.
Wird ein Motor ohne Abtriebselement in Betrieb genommen,

so ist die Pafeder gegen Herausschleudern zu sichern.
Alle Arbeiten nur im elektrisch spannungslosen Zustand der Anlage

durchfhren.
2.4
Elektrischer Anschlu
Netzspannung und Netzfrequenz mssen mit den Daten auf dem

Leistungsschild bereinstimmen. 5% Spannungs- oder Frequenzabweichung (1ME6 3% Frequenzabweichung) sind ohne Leistungsherabsetzung zulssig. Anschlu und Anordnung der Schaltbgel nach dem im Klemmenkasten befindlichen Schaltbild vorneh-
Transport, Lagern
Beim Transport sind alle vorhandenen Hebesen am Motor zu

benutzen!
men. Schutzleiter an diese Klemme
Zum Transport von Maschinenstzen

WARNUNG
(z. B. Getriebe-, Geblseanbauten, ...)
nur die dafr vorgesehenen Hebesen
bzw. -zapfen benutzen! Maschinenstze drfen nicht durch
Anhngen an den Einzelmaschinen gehoben werden! Auf
Tragfhigkeit dieser Hebeeinrichtung achten!
anschlieen.
Bei Anschluklemmen mit Klemmbgeln (z. B. nach DIN 46282)

sind die Leiter so zu verteilen, da auf beiden Stegseiten etwa
gleiche Klemmhhen entstehen. Diese Anschluart erfordert
daher, da ein einzelner Leiter U-frmig gebogen werden mu
oder mit einem Kabelschuh anzuschlieen ist (s. Fig. 3.1). Dies
gilt auch fr den Schutzleiteranschlu und den ueren Erdungsleiter (s. Fig. 3.2) - grngelb .
Die Wlzlager sollten neu gefettet bzw. erneuert werden, wenn

die Zeit von der Lieferung bis zur Motorinbetriebnahme bei gnstigen Bedingungen (Aufbewahrung in trockenen, staub- und erschtterungsfreien Rumen) mehr als 3 Jahre betrgt. Bei ungnstigen
Bedingungen verringert sich diese Zeit wesentlich.
Anziehdrehmomente fr Schraubenverbindungen der elektrischen

Anschlsse - Klemmenbrettanschlsse (auer Klemmenleisten)
s. Fig. 4.
Ggf. ist der Isolationswiderstand der Wicklung zu berprfen, s.

Abschnitt 2.5 .
2.5
2.2
Vor der Erstinbetriebnahme des Motors, nach lngerer Lagerung

oder Stillstandzeit (ca. 6 Monate), mu der Isolationswiderstand
der Wicklungen ermittelt werden.
Aufstellung
Eingeschraubte Hebesen sind nach dem Aufstellen festanzuziehen oder zu entfernen!
WARNUNG
Bei Motoren mit Wellenende nach oben oder unten (z.B. IMV5,
IMV6 - s. Fig. 1) mu gewhrleistet sein, da kein Wasser in das
obere Lager eindringen kann.
berhrt werden.
Laufruhe
Stabile Fundamentgestaltung oder An- und Einbauverhltnisse,
genaues Ausrichten der Motoren sowie ein gut ausgewuchtetes
Abtriebselement sind Voraussetzung fr einen ruhigen schwingungsarmen Lauf. Z. B. sind dnne Bleche unter die Fe zu legen,
um ein Verspannen der Motoren zu vermeiden oder ggf. kann ein
komplettes Auswuchten des Lufers mit dem Abtriebselement erforderlich sein.
- Der kritische Isolationswiderstand Rkrit wird zunchst errechnet. Berechnung erfolgt durch Multiplikation der Bemessungsspannung UN, z. B. AC 0,69 kV, mit dem konstanten Faktor (0,5
MegaOhm/kV):
R krit = 0,69 kV * 0,5 MegaOhm/kV = 0,345 MegaOhm
Messung
Der Mindestisolationswiderstand der Wicklungen gegen Masse
wird mit 500 V Gleichspannung gemessen. Dabei soll die Temperatur der Wicklungen 25C 15C betragen.
Wuchtung, Abtriebselemente
Der kritische Isolationswiderstand ist bei Betriebstemperatur der

Wicklung mit 500 V Gleichspannung zu messen.
Das Auf- und Abziehen von Abtriebselementen (Kupplungen Riemenscheiben, Zahnrad, ...) ist mit einer geeigneten Vorrichtung
auszufhren (Fig. 7).
berprfung
Ist bei neuer, gereinigter oder instandgesetztem Motor, der lngere
Zeit gelagert wurde oder still stand, der Mindestisolationswiderstand der Wicklung gegen Masse kleiner 10 MegaOhm, kann die
Ursache hierfr Feuchte sein. Die Wicklungen sind dann zu trocknen.
Standardmig sind die Lufer mit einer halben Pafeder dynamisch ausgewuchtet.
Die Art der Auswuchtung wird am AS-Wellenende (Wellenstirnseite) markiert:
(H = Auswuchtung mit halber Pafeder
(F = Auswuchtung mit ganzer Pafeder-Sonderausfhrung)
Nach lngerer Betriebsdauer kann der Mindestisolationswiderstand auf den kritischen Isolationswiderstand absinken. Solange
der gemessene Wert den errechneten Wert des kritischen Isolationswiderstandes nicht unterschreitet, darf der Motor weiter betrieben werden. Wird dieser Wert unterschritten, ist der Motor sofort abzuschalten.
Bei Montage des Abtriebselementes auf entsprechende

Auswuchtart achten!
Auswuchtung mit halber Pafeder
Bei Abtriebselementen mit einem Lngenverhltnis von Nabenlnge l zur Lnge des Wellenendes lM < 0,8 und Drehzahlen >
1500/min knnen Laufruhestrungen auftreten (s. Fig. 8).

Siemens AG
Bei und unmittelbar nach der Messung

haben die Klemmen teilweise gefhrliche Spannungen und drfen nicht
Isolationswiderstand
- Der Mindestisolationswiderstand von neuen, gereinigten oder
instandgesetzten Wicklungen gegen Masse betrgt 10 MegaOhm.
Das Klemmenkastenoberteil kann bei einem Klemmenbrett mit

6 Anschluklemmen um 4x90 Grad und bei einem Klemmenbrett
mit 9 Anschluklemmen um 180 Grad gedreht werden.
2.3
berprfung des Isolationswiderstandes
Es ist die Ursache hierfr zu ermitteln, ggf. sind die Wicklungen

oder Wicklungsteile instand zusetzen, zu reinigen oder zu trocknen.
-2-
DEUTSCH
2.6
Inbetriebnahme
Lagerwechsel, Fettstandzeit, Fettsorte
HINWEIS: Bei stark ungleichfrmigem Drehmoment (z.B. Antrieb eines Kolbenkompressors) wird ein nicht-sinusfrmiger Motorstrom erzwungen, dessen Oberschwingungen sowohl eine unzulssige Netzbeeinflussung als auch unzulssig hohe elektromagnetische Straussendungen bewirken knnen.
Die Fettstandzeit betrgt unter normalen Betriebsbedingungen, bei

waagerechter Motoraufstellung, Khlmitteltemperatur bis 40C und
einer Motordrehzahl von
- 1500/min ca. 40 000 Betriebsstunden
- 3000/min ca. 20 000 Betriebsstunden.
Bei Speisung durch Umrichter knnen hochfrequente Strom- und

Spannungsoberschwingungen in den Motorzuleitungen zu elektromagnetischen Straussendungen fhren. Deshalb wird die Verwendung abgeschirmter Zuleitungen empfohlen.
Unabhngig von den Betriebsstunden sollte das Fett, wegen der

Alterung, etwa alle 3 Jahre erneuert werden. Dazu sind die Lager
zu demontieren auszuwaschen und neu zu beffeten. Bei Ausfhrung mit Nachschmierung sind die Schmierschildangaben zu
beachten.
Vor Inbetriebnahme ist zu prfen ob:

- die Mindestisolationswiderstnde eingehalten sind
Bei besonderen Betriebsbedingungen, z. B. senkrechter Motoraufstellung, hufigem Betrieb bei der Grenzdrehzahl nmax, groen Schwingungs- und Stobelastungen, hufigem Reversierbetrieb, reduzieren
sich die vorstehend genannten Betriebsstunden wesentlich.
- der Lufer ohne anzustreifen gedreht werden kann

- der Motor ordnungsgem montiert und ausgerichtet ist
- die Abtriebselemente richtige Einstellbedingungen haben (z. B.
Riemenspannung bei Riementrieb; ...) und das Abtriebselement
fr die Einsatzbedingungen geeignet ist
Die Motoren haben standardmssig Rillenkugellager der Reihe 62

. . oder mit Option K36 Rillenkugellager der Reihe 63 . . mit einer
Deckscheibe (ZC3 Ausfhrung).
- alle elektrischen Anschlsse sowie Befestigungsschrauben und

Verbindungselemente nach Vorschrift angezogen und ausgefhrt sind
Die Deckscheibe ist auf der dem Motorgehuse (Stnder) zugewandten Lagerseite angeordnet.
- der Schutzleiter ordnungsgem hergestellt ist
HINWEIS: Beim Lagerwechsel ist auf die Anordnung der Deckscheibe und die Lagerluft zu achten, da bei Sonderausfhrungen
von der Standardausfhrung abgewichen werden kann!
- eventuell vorhandenen Zusatzeinrichtungen (Bremse, Tacho,

Fremdlfter) funktionsfhig sind
Fettsorte bei Standardmaschinen: (Fa. ESSO ) UNIREX N3);

Fettstandzeiten und Nachschmierfristen gelten nur in Verbindung
mit dieser Fettsorte.
- Berhrungsschutzmanahmen fr bewegte und spannnungsfhrende Teile getroffen sind

- die Grenzdrehzahl nmax (s. Leistungsschild) nicht berschritten
wird;
HINWEIS: Die Grenzdrehzahl nmax ist die hchste kurzzeitig
zulssige Betriebsdrehzahl. Es ist zu beachten, da sich hierbei das Gerusch- und Schwingungsverhalten des Motors verschlechtert sowie die Lagerwechselfrist verringert.
VORSICHT
Ersatzfette mssen mind. der DIN 51825-KL3N gengen. Hierbei

sind Schmierfristen bei KT > 25 oC zu reduzieren.
Sonderfette sind auf dem Schmierschild angegeben.
Das Mischen von verschiedenen Fettsorten ist zu vermeiden!
Motor im erforderlichen Umfang zerlegen. Wlzlager mit geeigneter
Vorrichtung abziehen (s. Fig. 6). Lagerstelle von Verunreinigungen subern! Wlzlager reinigen bzw. erneuern und neu fetten.
Nach dem Anbau der Motoren ist die

Bremse (falls vorhanden) auf ihre einwandfreie Funktion zu prfen!
Hohlrume der Wlzlager bndig mit Schmierfett fllen! Lagerdeckel bzw. Lagerschild bleibt ohne Fettfllung, um eine berfettung
zu vermeiden.
Wlzlager gleichmig auf ca. 80-100C erwrmen und aufziehen.
Harte Schlge (z. B. mit einem Hammer, ...) sind zu vermeiden.
Diese Aufzhlung kann nicht vollstndig sein. Zustzliche

Prfungen sind gegebenenfalls ntig!
Instandhaltung
Eventuell abgentzte Dichtelemente (z. B. Wellendichtring, usw.),

sind ebenfalls zu erneuern.
Sicherheitsmanahmen
Sind Radial-Wellendichtringe ohne Feder eingebaut, so mu auch

das Ersatzteil ohne Feder eingesetzt werden.
Vor Beginn jeder Arbeit am Motor

oder Gert, besonders aber vor
dem ffnen von Abdeckungen aktiver Teile, mu der Motor vorschriftsmig freigeschaltet
sein. Neben den Hauptstromkreisen ist dabei auch auf eventuell vorhandene Zusatz- oder Hilfsstromkreise zu achten.
Die blichen 5 Sicherheitsregeln lauten hierbei z. B. nach
DIN VDE 0105:
WARNUNG
Nachschmiereinrichtung
Bei Motoren mit Nachschmiereinrichtung sind die Angaben auf
dem Schmierschild zubeachten!
Fugenabdichtung
Beim Zusammenbau von Maschinen der Schutzart IP 55 oder hher
(s. Leistungsschild) mssen die blanken Montageflchen zwischen
dem Motorgehuse und den Lagerschilden durch eine geeignete,
nicht aushrtende Dichtungsmasse abgedichtet werden (z. B. Hylomar, Curil).
- Freischalten
- Gegen Wiedereinschalten sichern
- Spannungsfreiheit feststellen
Kunststofflfter (BG180M ... 315L)

Kunststofflfter haben jeweils zwei angegossene Zungen, die als
Axialfixierung in die Ringnut der Welle einrasten. Vor dem Abziehen des Lfters mssen die beiden Zungen ausgerastet
(Schraubendreher) und in dieser Position, z.B. durch eingeschobene Beilagen, provisorisch festgehalten werden. Die Lfter
haben in der Tragscheibe zwei ffnungen zum Durchfhren einer
Abziehvorrichtung, die an der Nabe sind angreift.
- Erden und Kurzschlieen

- Benachbarte unter Spannung stehende Teile abdecken oder
abschranken.
Diese zuvor genannten Manahmen drfen erst dann
zurckgenommen werden, wenn die Instandhaltungsarbeiten abgeschlossen sind und der Motor vollstndig montiert ist.
Die ffnungen sind bei Auslieferung mit einer dnnen Kunststoffhaut verschlossen, und mssen durchstoen werden.
HINWEIS: Verschlossenen Kondenswasserffnungen, mssen

von Zeit zu Zeit geffnet werden, damit eventuell angesammeltes
Kondenswasser abflieen kann.
Zum Abziehen wie auch zum Aufziehen mu grundstzlich eine

geeignete Vorrichtung verwendet werden. Hammerschlge sind
hierbei unbedingt zu vermeiden, um die Lager zu schtzen.
Kondenswasserffnungen sind stets an der tiefsten Stelle des

Motors anzuordnen!
Es ist auf das Einrasten der Schnappnasen in der Wellennut zu

achten.

Siemens AG
-3-
ENGLISH
If, after delivery, the motors are stored for more than 3 years under
favourable conditions (kept in a dry place free from dust and vibration) prior to commissioning, the bearings should be regreased.
General note
The data and recommendations specified in all the instructions supplied,
and in all other related instructions,
must always be observed in order to avoid hazardous situations and the risk of possible injury or damage.
WARNING
Under unfavourable conditions, this period is considerably shorter.

If necessary, the insulation resistance of the winding should be
checked, see Section 2.5.
These instructions are augmented by supplementary instructions (yellow), which contain additional information on the safety measures for electrical machines and devices. The latter
instructions thus augment all submitted instructions and all other
related instructions.
2.2
After installation, screwed-in lifting eyes should either be removed

or tightened down.
Furthermore, the pertinent national, local and plant-specific

regulations and requirements should be kept in mind!
In the case of motors with shaft end facing upwards or downwards (such as IMV5, IMV6 - see Fig. 1), measures must be taken to ensure that no water can penetrate into the upper bearing.
In the case of terminal boards with 6 terminals, the top part of the
terminal box can be turned through 4 x 90 degrees. For terminal
boards with 9 terminals, it can be turned through 180 degrees.
Special designs and other versions may vary in technical

details! If in doubt, be sure to contact the manufacturer, quoting the type designation and serial number, or have maintenance work done by one of SIEMENS Service Centres.
Quiet running
Stable foundations or mounting conditions, exact alignment of the
motors and a well-balanced transmission element are essential
for quiet vibration-free running. If necessary, shims should be inserted under the motor feet to prevent strain, or the whole rotor
and transmission element should be balanced.
NOTE: Fig. 2 ... (Spare Parts) see Annex page 29
1.1
Description
Application
The motors are suitable for operation in dusty and damp environments. The insulation is tropicalized. If they are properly stored or
installed outdoors, special weatherproofing measures are not usually required.
2.3
As standard, the rotors are dynamically balanced with the half

featherkey inserted.
The type of balance is marked on the drive end of the shaft (shaft
end face):
(H = balanced with half featherkey)
(F = balanced with whole featherkey)
Construction and mode of operation
The 1LG4, 1LG6 and 1LG9 motors are standardly self-ventilated

with own fans. In addition to that the 1LG motors are optionally
either without an own fan (such as fan motors with cooling by means
of a separate fan arranged on the shaft end) or with external coolling (option G17). The 1PP4, 1PP6 and 1PP9 motors are equipped
with own cooling without any fan.
When fitting the transmission element, keep the type of balance in mind!
Balance with half featherkey
Poor running characteristics can arise in the case of transmission
elements having a length ratio of hub length l to length of shaft end
l M < 0.8 and running at speeds of > 1500 rev/min (see Fig. 8). If
necessary, re-balancing should be carried out, e.g. the part of the
featherkey Tp that protrudes from the transmission element and
above the shaft surface should be cut back.
The feet on foot-mounted motors are cast integrally with the motor
casing or they can be optionally bolted onto the casing (option
K11 / see fig. 2).
Rearranging the feet (e.g. for changing the position of the terminal
box) is possible for options K09, K10 and K11. The bores and
surfaces, necessary for this purpose, are already machined in a
corresponding way.
The usual measures should be taken

to guard transmission elements from
touch. If a motor is started up without
transmission element attached, the
featherkey should be secured to prevent it being thrown out.
WARNING
Where motors with brake are concerned (e.g. option G26), take
into consideration also the brake operating instructions!
These instructions are valid in addition to the operating instructions of the given motor type. They are not valid for motors of
EEx e series.
Operation
WARNING
2.1
2.4
conductor to the terminal with the marking
Transport, storage
Wherever terminal clips are used (for example, to DIN 46282),

arrange the conductors so the clips are virtually level, i.e. not
tilted when tightened. This method of connection means that
the ends of single conductors must be bent in the shape of a
U or be fitted with a cable lug (see Fig. 3.1). This also applies
to the green-yellow protective earthing conductor and the outer
earthing conductor (see Fig. 3.2).
The motors should always be lifted at both lifting eyes during

transport.
For lifting machine sets (such as builton gearboxes, fan units), always use
the lifting eyes or lifting pegs provided! Machine sets may not be lifted by
suspending the individual machines! Check the lifting capacity of the hoist!
WARNING
Siemens AG
Check to see that system voltage and frequency agree with the
data given on the rating plate. Voltage or frequency deviations of
5% (for 1ME6, frequency deviations of 3%) from the rated values are permitted without the necessity of derating the output.
Connection and arrangement of the terminal links must agree with
the diagram provided in the terminal box. Connect the earthing
Before starting any work on the machine, be sure to isolate it from the
power supply.

Balancing, transmission elements
A suitable device should always be used for fitting and removing

the transmission elements (coupling halves, pulleys, pinions) (Fig.
7).
Measuring-surface sound-pressure level at 50 Hz

(DIN EN 21 680 Part 1)
1LG4, 1LG6, 1LG9
approx. 51 to 76 dB(A)
1.2
Installation
Please refer to Fig. 4 for tightening torques for terminal bolts and
nuts (except for terminal strips).
-4-
ENGLISH
2.5
Checking the insulation resistance
It is not possible to formulate a complete check list. Other

checks may also be necessary!
The insulation resistance of the windings must be measured prior

to initial startup of the machine, after long periods of storage or
standstill (approx. 6 months).
WARNING
While the measurement is being taken and immediately afterwards, some

of the terminals carry dangerous voltages and must not be touched.
Maintenance
Safety precautions
Before starting any work on the
motor or other equipment, particularly before opening covers over
live or moving parts, the motor must be properly isolated
from the power supply. Besides the main circuits, any additional or auxiliary circuits that may be present must also
be isolated.
WARNING
Insulation resistance
- The minimum insulation resistance of new, cleaned or repaired windings with respect to ground is 10 MOhm.
- The critical insulation resistance Rcrit is calculated first by multiplying the rated voltage UN, e.g. 0.69 kV AC, with the constant
factor (0.5 MOhm/kV):
The usual 5 safety rules (as set forth in DIN VDE 0105)
are:
Rcrit = 0.69 kV * 0.5 MOhm/kV = 0.345 MOhm.
- Isolate the equipment
Measurement
The minimum insulation resistance of the windings to ground is
measured with 500 V DC. The winding temperature should then
be 25oC 15 oC.
- Take effective measures to prevent reconnection

- Verify equipment is dead
- Earth and short-circuit
The critical insulation resistance should be measured with 500

V DC with the winding at operating temperature.
Checking
If the minimum insulation resistance of a new, cleaned or repaired machine, which has been stored or at standstill for a prolonged period of time, is less than 10 MOhm, this may be due to
humidity. The windings must then be dried.
- Cover or fence off adjacent live parts

The precautions listed above should remain in force until
all maintenance work is finished and the motor has been
fully assembled.
NOTE: Where motors are fitted with closed condense water openings, these should be opened from time to time to allow any accumulated condense water to be drained away.
After long periods of operation, the minimum insulation resistance may drop to the critical insulation resistance. As long as
the measured value does not fall below the calculated value of the
critical insulation resistance, the machine may continue in operation. If it does, the machine must be stopped immediately.
Condense water openings should always be at the lowest point of

the motor!
The cause must be determined, and the windings or winding sections repaired, cleaned or dried as necessary.
Fitting new bearings, grease lifetime, type of

grease
2.6
Under normal operating conditions, with horizontally mounted

motors and coolant temperatures up to 40 C, the grease lifetime
should be:
Commissioning
NOTE: Where the torque is very uneven (the drive of a piston-type

compressor, for example), the inevitable result is a non-sinusoidal
motor current, whose harmonics can lead to excessive system
perturbation or excessive electromagnetic interference.
- approx. 40,000 operating hours for speeds of 1500 rpm

- approx. 20,000 operating hours for speeds of 3000 rpm
Irrespective of the number of operating hours, the grease should
be renewed every 3 years because of ageing. In this case the
bearings should be dismounted, washed and newly greased. The
modifications with additional greasing are to be maintained according to instructions on the lubricating data plate.
In the case of converter-fed motors, high-frequency current or voltage harmonics in the motor cables can give rise to electromagnetic interference. That is why the use of shielded cables is recommended.
Before commissioning, check that:
- The minimum insulation resistances are adhered to
- The rotor turns freely without rubbing
In the case of motors operating under special conditions, such as

vertical motor position, frequent operation at maximum speed nmax,
heavy vibration, sudden load changes and frequent reversing operation, the bearing should be changed at considerably more frequent intervals than at the operating hours stated above.
- The motor is properly assembled and aligned

- The transmission elements are correctly adjusted (e.g. belt tension) and the transmission element is suitable for the given operating conditions
The motors are standardly equipped with radial ball bearings of 62

series or with option K36 - radial ball bearings of 63 series
which are provided with a cover plate (ZC3 version).
- All electrical connections, mounting screws and connecting elements are properly tightened and fitted
The cover plate is arranged on that side of the bearing facing the
frame (stator).
NOTE: Notice the cover plate arrangement and the bearing clearance when changing the bearings because standard modifications
can differ from special motors!
- All protective conductors are properly installed

- Any auxiliaries that may be fitted (brakes, speedometer, separate fan) are in working order
- Touch protection guards are installed around moving and live
parts
The cover plate material should withstand temperatures from 20 C to +150 C, e.g. polyacryl-rubber (ACM).
- The maximum speed nmax (see rating plate) is not exceeded.
Type of grease for standard machines: (Fa. ESSO / UNIREX

N3); grease lifetime and lubrication intervals are valid for this type
of grease only.
NOTE: The maximum speed nmax is the highest operating speed

permitted for short periods. It should be kept in mind that motor
noise and vibration are worse at this speed, and bearing life is
reduced.
CAUTION

Siemens AG
Compensatory greases must conform to DIN 51825-KL3N at least.

In this case the lubrication intervals at KT > 25 C are to be reduced.
After motor installation, the brake, if

fitted, should be checked for proper
functioning.
-5-
ENGLISH
Special greases are introduced on the lubricating data plate.
Avoid mixing different types of grease!
Dismantle the motor to the extent necessary. Pull off the bearing
with a suitable device (see Fig. 6). Clean the journal! Clean the
bearing, or obtain a new one, and pack it with fresh grease.
Pack the bearing cavities flush with grease! The cover plate or
endshield is kept free of grease to prevent overgreasing.
Heat bearings evenly to about 80-100 C and press on. Heavy
blows (such as with a hammer, ...) should be avoided.
Any worn sealing elements (such as shaft sealing ring, etc.) should
also be renewed.
If springless radial shaft sealing rings are used, the replacement
sealing rings must also be of the springless type.
Regreasing device
In the case of motors with regreasing device, take note of the
information given on the lubricating data plate!
Joint sealing
When reassembling machines with degree of protection IP55 or
higher (see rating plate), the bright surfaces of the joint between
the motor frame and the endshields should be coated with a suitable non-hardening sealing compound (such as Hylomar, Curil).
Plastic fan (frame sizes 180M ... 315L)
Plastic fans have two cast-on tabs that snap into the ring groove
on the shaft to prevent axial movement. Before the fan is pulled off
the shaft, these two tabs must be disengaged (screwdriver) and
held temporarily in that position, e.g. by inserting packing. In the
disc at the root of the blades, there are two openings for the claws
of an extractor whose central screw should press against the hub.
On delivery, these openings may be covered by a film of plastic
and later on they should be punched.
A suitable device should be used for pulling the fan off and pressing it back on. Hammer blows must be avoided to protect the bearings.

Siemens AG
-6-
FRANAIS
que par les oeillets ou chevilles dlingage prvus cet effet.
Ils ne doivent pas tre levs par les machines individuelles.
La charge limite du dispositif de levage doit tre respecte.
Remarque gnrale
Afin dassurer la protection des personnes et dviter tout dgt matriel, il est impratif de respecter les indications contenues dans toutes les instructions de service et
dans tous les autres lments de documentation transmis avec
le produit.
Les instructions jointes (sur papier jaune) contiennent des rgles de scurit applicables aux matriels lectriques. Ces informations relatives la scurit doivent tre utilises en complment de lensemble de la documentation.
ATTENTION
Dans des conditions dentreposage favorables (dans des locaux

secs, labri de poussires et de trpidations), regraisser ou remplacer les roulements billes sil sest coul plus de 4 ans entre
la livraision et la mise en service du moteur. Dans des conditions
dfavorables, cette priode sera plus courte en consquence.
Ler cas chant, contrler la rsistance disolement des enroulements (voir chap. 2.5).
2.2
Toutes les prescriptions et exigences nationales, locales

ou spcifiques linstallation doivent tre respectes.
Aprs linstallation, serrer ou enlever les oeillets de levage visss.
Les machines de ralisation spciale (version, forme de construction) peuvent diffrer quant aux dtails techniques. En cas
de doute ce sujet, il est instamment recommand de contacter lagence Siemens comptente en indiquant la dsignation de type et le numro de fabrication, ou de recourir aux
centres de S.A.V. Siemens pour effectuer les travaux de maintenance.
Sur les moteurs bout darbre vers le haut ou vers le bas

(p.ex. IMV5, IMV6, voir Fig. 1), prendre les dispositions pour protger le palier suprieur contre la pntration deau.
La partie suprieure des botes bornes avec plaques de bornes
six bornes peut tre tourne de 4 x 90; la partie suprieure des
botes bornes avec plaques de bornes 9 bornes peut tre
tourne de 180.
Comportement vibratoire
La stabilit des fondations et des supports de montage, la prcision de lalignement des machines et lquilibrage soign des organes de transmission sont les conditions dun bon comportement
vibratoire. Cest ainsi quil faudra par exemple interposer sous les
pattes des cales en tle pour empcher le gauchissement du
moteur ou procder lquilibrage du rotor complet avec les lments de transmission.
NOTA Fig. 2 ...(Pices de rechange) voir appendice pages 29
1.1
Description
Domaine dapplication
Les moteurs peuvent tre installs en atmosphre poussireuse

et humide. Lisolation est tropicalise. Normalement, aucune
mesure de protection particulire contre les intempries nest
ncessaire si lon entrepose correctement les moteurs ou si on les
monte lextrieur selon les rgles de lart.
2.3
Les moteurs en version standard ont fait lobjet dun quilibrage dynamique avec demi-clavette.
Le type dquilibrage est indiqupar un marquage au bout de larbre
(ct de la commande au front de larbre):
(H = quilibrage avec demi-clavette)
(F = quilibrage avec clavette entire-version spciale)
Constitution et mode de fonctionnement
Les moteurs 1LG4, 1LG6 et 1LG9 en version standard sont autorefroidis par ventilateur. En outre, les moteurs de la srie 1LG
peuvent etre soit sans le propre ventilateur (par ex. les moteurs de
ventilateur refroidis par un ventilateur spcial mont au bout de
larbre), soit en excution a refroidissement tranger (option G17).
Les moteurs 1PP4, 1PP6 et 1PP9 sont autorefroidis sans ventilateur.
Lors du montage de lorgane de transmission, veiller ce que le

type dquilibrage de ce dernier corresponde celui du rotor.
Equilibrage avec demi-clavette
Pour les organes de transmission dont le rapport de la longueur
de moyeu la longueur lM du bout darbre est < 0,8 et pour des
vitesses > 1500 tr/min, il peut se produire des balourds (voir Fig.
8).
Les pattes des moteurs sont coules sur la carcasse, il y a aussi

une option a pattes visses la carcasse (option K11 / voir Fig. 2).
Les options K09, K10 et K11 permettent le dplacement des pattes
sur la carcasse, par exemple pour modifier la position de la rglette de bornes. Il y a dja les alsages ncessaires et les surfaces sont dja usines de faon correspondante.
Effectuer le cas chant un rquilibrage aprs avoir par exemple

limin lexcdent de matire TP de la clavette qui fait saillie par
rapport au moyeu et larbre.
Pour les moteurs avec frein (par exemple option G26), il convient
dobserver en plus les instructions de service du frein!
Ces instructions sont valables en qualit dun complment des
instructions de service du modele correspondant du moteur. Elles
ne concernent pas les moteurs en version EEx e.
2.1
Prendre les mesures habituelles de

protection des personnes contre
laccs aux parties en mouvement au
niveau des organes de transmission. Lorsquun moteur est
mis en marche sans organes de transmission, prendre les
mesures ncessaires afin dempcher que la clavette ne soit
projete hors de larbre par force centrifuge.
ATTENTION
Fonctionnement
ATTENTION
Avant toute intervention sur la machine, vrifier quelle est bien hors tension.
2.4
Pour la manutention, utiliser tous les oeillets de levage disponibles sur le moteur.
Les groupes de machines (par ex.
motorducteurs, motocompresseurs,
etc.) ne doivent tre manutentionns

Siemens AG
Raccordement lectrique
Comparer la tension et la frquence du rseau aux indications de

la plaque signaltique. Une variation de 5 % de la tension ou de
la frquence (pour 1MA5/1MF5 de 3 % de la frquence) est admissible sans dclassement en puissance. Raliser le branchement et disposer les barrettes de couplage conformment au schma situ dans la bote bornes. Raccorder le conducteur de pro-
Transport, manutention et stockage
ATTENTION
Equilibrage, organes de transmission
Lemmanchement et lextraction des organes de transmission

(demi-accouplements, poulies, roues demtes,...) devront se faire
avec les dispositifs appropris (Fig. 7).
Niveau de pression acoustique 50 Hz (DIN EN 21680, fasc. 1)

1LG4, 1LG6, 1LG9
env. 51 76 dB(A)
1.2
Installation
tection la borne
-7-
FRANAIS
Les conducteurs raccords des bornes trier doivent tre
disposs de telle sorte que ltrier repose la mme hauteur
de part et dautre de la vis. Lorsquun seul conducteur est
raccord, il doit tre pli en U autour de la vis ou tre muni
dune cosse (voir Fig. 3.1). Il en est de mme du conducteur
de protection et le conducteur de terre externe vert jaune (voir
Fig. 3.2).
- le moteur est mont et align correctement,

- les organes de transmission sont correctement rgls (par ex.
tension de courroie) et bien choisis pour lemploi,
- les connexions lectriques sont ralises conformment aux
prescriptions, et les vis des bornes sont serres aux couples
prescrits,
Couples de serrage des vis et crous des bornes de la plaque

bornes (ne concerne pas les borniers), bvoir Fig. 4.
- le conducteur de protection est bien raccord,

- les dispositifs additonnels ventuels (freins, compte-tours, ventilateur externe) sont oprationnels,
2.5
- les mesures de protection des personnes contre laccs aux

parties actives (sous tension) ou en mouvement ont t prises,
Contrle de la rsistance disolement
Avant la premire mise en service de la machine, aprs un entreposage de longue dure ou encore une interruption de service
prolonge (env. 6 mois), la rsistance disolement des enroulements doit tre mesure.
ATTENTION
- la vitesse limite nmax (lorsquelle est indique, voir plaque signaltique) ne doit pas tre dpasse.
NOTA : la vitesse limite nmax est la vitesse de service maximale
temporaire. A cette vitesse, on observe une dgradation du comportement sonore et vibratoire ainsi quun raccourcissement de
la priode de renouvellement des roulements.
Durant la mesure et immdiatement

aprs, les bornes sont portes en partie une tension dangereuse et ne
doivent pas tre touches.
ATTENTION
Rsistance disolement
- La rsistance minimale disolement mesure par rapport la
masse est de 10 Mgohms pour les enroulements neufs, nettoys ou remis en tat.
La prsente numration ne peut tre exhaustive. Des contrles supplmentaires peuvent savrer ncessaires.
- La rsistance critique disolement Rkrit se calcule en multipliant la tension assigne U N, p.ex. 0,69 kV CA, par la constante
0,5Mgohms/kV :
Avant toute intervention sur le moteur, notamment avant douvrir ou

denlever les recouvrements des
parties actives, il est indispensable de mettre le moteur
hors tension conformment aux rglements de scurit.
En plus des circuits principaux, ne pas oublier les ventuels circuits auxiliaires et additionnels.
ATTENTION
La temprature des enroulements en cours dessai doit tre de 25

15C.
La rsistance critique disolement doit tre mesure avec une
tension dessai continue de 500 V lorsque les enroulements ont
atteint leur temprature en service.
Contrle
La rsistance minimale disolement par rapport la masse
mesure sur les enroulements de machines ayant t entreposes
pendant une priode prolonge, ou encore sur des enroulements
neufs, nettoys ou remis en tat peut tre infrieure 10 Mgohms en raison de lhumidit rgnant au niveau des enroulements.
Dans ce cas, scher les enroulements.
Les 5 rgles de scurit (par exemple selon DIN VDE 0105)

sont applicables :
- mettre hors tension
- condamner les appareils (contre le renclenchement)
- vrifier labsence de tension
- mettre la terre et court-circuiter
- recouvrir les parties actives voisines ou en barrer laccs.
Ces mesures de scurit ne doivent tre supprimes qu
lissue de lintervention de maintenance et lorsque tous
les lments du moteur sont remonts.
Aprs un service prolong, la valeur de la rsistance minimale

disolement peut se rapprocher de la valeur de la rsistance critique disolement. Tant quelle ne tombe pas en-dessous de cette dernire, la machine peut rester en fonctionnement. Dans le
cas contraire, la machine doit tre arrte immdiatement.
NOTA : Dans la mesure o le moteur doit fonctionner avec purgeurs

de condensat ferms (par ex. en degr de protection IP55 ou IP56),
il faut ouvrir de temps en temps les purgeurs de leau condense
pour pouvoir vacuer leau condense ventuellement accumule.
Il faudra alors en dterminer la cause, et ventuellement remettre

en tat, nettoyer ou scher les enroulements en totalit ou en
partie.
Les purgeurs de condensats sont toujours installer au point le

plus bas du moteur.
Mise en service
Remplacement des roulements, dure dusage du

lubrifiant, types des graisses de lubrification
NOTA : Un couple trs irrgulier (par ex. lors de lentranement

dun compresseur piston) donne lieu un courant moteur non
sinusodal dont les harmoniques sont susceptibles de polluer exagrment le rseau dalimentation ou dmettre des perturbations
lectromagntiques.
Dans des conditions de service normales, avec moteur axe horizontal et temprature dair de refroidissement jusqu 40 C, la
dure dusage du lubrifiant est de
Lors de lalimentation par convertisseurs statiques, les cbles

vers le moteur peuvent tre le sige dharmoniques de courant et
de tension haute frquence qui sont la source dmissions de
perturbations lectromagntiques. Ceci oblige utiliser des cbles dalimentation blinds.
- 40 000 heures de service 1500 tr/min,

- 20 000 heures de service 3000 tr/min.
Pour des raisons de vieillissement, la graisse devrait tre renouvele tous les 3 ans, indpendamment du nombre dheures de
service. Pour povoir le faire, il faut dmonter les roulements, les
laver et graisser par la graisse neuve. Pour les versions o il faut
priodiquement ajouter la graisse, suivre les donnes de la plaque
de graissage.
Avant mise en service, vrifier les points suivants :

- la rsistance disolement minimale est respecte,
- le rotor peut tre tourn sans quil frotte,

Siemens AG
Maintenance
Dispositions gnrales concernant la scurit
R krit = 0,69 kV * 0,5 Mgohms/kV = 0,345 Mgohms

Mesure
La rsistance minimale disolement des enroulements par rapport la masse est mesure avec une tension dessai continue de
500 V.
2.6
Aprs montage de la machine,

sassurer que le frein (si prsent) est
en bon tat de fonctionnement.
-8-
FRANAIS
Dans les conditions dutilisation particulires, par ex. axe vertical,
fonctionnement frquent la vitesse limite nmax , grandes sollicitations par des vibrations et chocs, inversion frquent du sens de
marche, etc., les nombres des heures de service indiqus ci-dessus sont beaucoup plus rduits.
Les moteurs sont quips en version standard de roulements
billes srie 62 ou loption K36 de roulements a billes srie
63 avec un couvre-palier (version ZC3).
NOTA : lors du remplacement des roulements, veiller lorientation
du dflecteur et au jeu des roulements, vu que sur les excutiuons
spciales la disposition peut diffrer de celle des excutions standard!
Les dflecteurs seront en matire rsistant aux tempratures entre -20 C et +150 C, par ex. caoutchouc de polyacryle (ACM).
Type de graisse (moteurs standards) : UNIREX N3 (Esso) ;
dure dusage des graisses et dlais de graissage sont valables
seulement pour ce type de graisse.
Les graisses de rechange doivent correspondre au minimum
DIN 51825-KL3N. Dans ce cas il faut rduire les intervalles de
graissage pour KT > 25oC.
Les graisses spciales sont spcifies sur la plaque de graissage.
Eviter de mlanger diffrentes sortes de graisses.
Dmonter le moteur dans la mesure du ncessaire. Lextraction
des roulements doit tre ralise avec un dispositif appropri (voir
Fig. 6). Nettoyer les portes de paliers ! Nettoyer les roulements
ou les remplacer et le regraisser.
Remplir ras de graisse les espaces libres des roulements ! Ne
pas mettre de graisse dans les couvercles de paliers ni dans les
flasques-paliers pour viter un excdent de graisse.
Porter progressivement les roulements une temprature denviron
80 100 C et les emmancher sur larbre. Eviter les coups secs
(par ex.: coups de marteau).
Remplacer galement tous les lments dtanchit soumis
usure (par exemple bagues dtanchit).
Les bagues dtanchit frottement radial sans ressort seront
remplaces par des bagues de mme type (sans ressort).
Dispositif de graissage
Pour les moteurs avec le dispositif de graissage, respecter les
indications figurant sur la plaque de graissage.
Pour les moteurs avec le dispositif de graissage, respecter les
indications figurant sur la plaque de graissage.
Etanchit des jointures
Lors du rassemblage des moteurs avec un degr de protection
IP 55 ou suprieur (voir plaque signaltique), les jointures en mtal
nu entre la carcasse et les flasques-paliers doivent tre tanches
avec un produit pteux ne durcissant pas (p. ex. Hylomar, Curil).
Ventilateurs en matire plastique (BG180M 315L)
Les ventilateurs en matire plastique comportent de moulage deux
languettes qui sengagent dans la gorge de larbre titre
dimmobilisation en translation. Avant dextraire le ventilateur, il
faut dgager les deux languettes (tournevis) et les maintenir provisoirement dans cette position par des cales. Les ventilateurs
comportent dans le disque raidisseur deux trous pour le passage
de larrache-moyeu qui sera fix sur le moyeu. A la livraison, ces
trous sont obstrus par un mince voile quil faut percer.
Lextraction et lemmanchement du ventilateur doivent tre raliss avec un dispositif appropri. Ne pas donner de coups de
marteau pour protger les roulements.
Il faut soccuper ce que les cliquets soient bien enfoncs dans
les cannelures de laxe.

Siemens AG
-9-
ESPAOL
mquinas no deben elevarse colgados de las mquinas individuales. Comprobar la capacidad de carga de estas anillas.
Indicaciones generales
Para evitar peligros y danos, es imprescindible observar siempre los
datos y las indicaciones que figuran
en todas las instrucciones de servicio y en las dems suministradas.
Los rodamientos se volvern a engrasar o se renovarn si han

transcurrido ms de 3 aos bajo condiciones favorables desde el
suministro hasta la puesta en servicio (conservacin en locales
secos, exentos de polvo y de trepidaciones). Si las condiciones
son desfavorables, este perodo se acorta considerablemente.
PRECAUCION
Estas instrucciones de servicio llevan adjuntas otras (de color

amarillo), que contienen datos suplementarios sobre la seguridad de las mquinas elctricas. Son por tanto un complemento de las dems instrucciones generales y de servicio suministradas.
En caso dado se comprobar la resistencia de aislamiento, v. apartado 2.5.
2.2
Emplazamiento
Adems rigen las condiciones y prescripciones vigentes nacionales, locales y especficas de la instalacin.
Las anillas atornilladas se apretarn o retirarn despus de la

instalacin.
Pueden diferir los detalles tcnicos de las ejecuciones especiales y variantes. En caso de dudas, es perentorio dirigirse
al fabricante indicando la designacin de tipo y el nmero
de serie, o dejar que un centro de service de SIEMENS efecte
los trabajos de conservacin.
En las mquinas de eje vertical (p. ej., IMV5, IMV6 - v. Fig. 1),
hay que garantizar que no pueda entrar agua en el rodamiento
superior.
INDICACION: Figs. 2 ... (Piezas de recambio), v. Anexo pgs. 29
Estabilidad de marcha
Son condiciones previas para lograr una marcha estable, con vibraciones reducidas, que la conformacin de los cimientos o las
condiciones de adosado/empotrado sean estables, junto con una
alineacin exacta de los motores y un buen equilibrado de los
elementos de accionamiento. Por ejemplo, se pueden colocar
chapas delgadas debajo de las patas para evitar las torsiones en
los motores o, en caso dado, puede que sea necesario un equilibrado completo del rotor junto con el elemento de accionamiento.
1.1
La parte superior de la caja de bornes con placa de 6 bornes se

puede girar en 4 x 90 grados y con placa de 9 bornes en 180
grados.
Descripcin
Campo de aplicacin
Los motores pueden instalarse en ambientes hmedos o polvorientos. El aislamiento es resistente al clima tropical. Normalmente
no es preciso adoptar medidas de proteccin especiales contra
los efectos climatolgicos, si los motores se almacenan o se depositan a la intemperie convenientemente.
2.3
Nivel de intensidad acstica en la superficie, a 50 Hz

(DIN EN 21 680, parte 1)
1LG4, 1LG6, 1LG9
aprox. 51 a 76 dB(A)
1.2
Se han de calar y extraer los elementos de accionamiento

(acoplamientos, poleas de transmisin, ruedas dentadas, ...)con
un dispositivo adecuado (Fig. 7).
Funcionamiento y constitucin
Los rotores estn equilibrados dinmicamente con media

chaveta de manera estndar.
A partir de las series de 1991, el tipo de equilibrado se marcar en
el LA del extremo del eje:
(H = equilibrado con media chaveta)
(F = equilibrado con chaveta entera ajustada ejecucin
especial)
Los motores 1LG4, 1LG6 y 1LG9 en su ejecucin bsica tienen

autorrefrigeracin por ventilador. Adems los motores de la serie
1LG pueden o bien no tener ventilador (opcin...., por ejemplo
como motores ventiladores con refrigeracin por medio de un
ventilador especial motado en el extremo del eje), o pueden tener
refrigeracin independiente (opcin G17). Los motores 1PP4, 1PP6
y 1PP9 son motores con refrigeracin propia sin ventilador.
Al montar el elemento de accionamiento observar que sea

adecuado el tipo de equilibrado.
En los motores con patas stas estn fundidas en la carcasa, al

pedido se pueden suministrar con las patas atornilladas (opcin
K11 / ver Fig. 2)..
Equilibrado con media chaveta

En los elementos de accionamiento con una relacin de la longitud de cuba I a la longitud del extremo del eje IM < 0,8 y velocidades > 1500/min, pueden aparecer irregularidades en la estabilidad de marcha (v. Fig. 8).
El traslado de las patas en la carcasa, por ejemplo para el cambio

de posicin de la caja de bornes (ver Fig.5), es posible en las
opciones K09, K10 y K11. Para esto ya estn adecuadamente
elaboradas las superficies y las perforaciones necesarias. En los
motores con freno (por ejemplo la opcin G26) es necesario
adems tener en cuenta las instrucciones de servicio del freno !
En caso dado ser necesario un reequilibrado, p. ej., mecanizar la

parte de la chaveta Tp que sobresale del elemento de accionamiento y del contorno del eje.
Estas instrucciones son vlidas como suplemento a las instrucciones de servicio del tipo de motor al que se refiera. No es vlido
para los motores con ejecucin EEx e.
Operacin
PRECAUCION
Se observarn las medidas generales

necesarias para la proteccin contra
contactos involuntarios de los elementos de accionamiento.
PRECAUCION
Si se opera un motor sin elemento de accionamiento, habr

que asegurar la chaveta contra su eyeccin.
En los motores solo se trabajar

cuando no estn bajo tensin.
2.4
2.1 Transporte, almacenamiento
Para transportar grupos de mquinas

(p. ej., reductores, ventiladores
adosados, ...) utilizar nicamente las
anillas o muones de suspensin previstos. Los grupos de
PRECAUCION
Siemens AG
Conexin
La tensin y frecuencia de la red tienen que ser las indicadas en la

placa de caractersticas. Son admisibles desviaciones de tensin
o de frecuencia de 5 % como mximo (para 1ME6, desviaciones
mximas de frecuencia de 3 %), sin que por ello disminuya la
potencia. Llevar a cabo el empalme y la colocacin de los estribos
de maniobra segn el esquema que se encuentra en la caja de
bornes. Empalmar el conductor de proteccin al borne marcado
Durante el transporte se utilizarn todas las anillas de suspensin

disponibles.

Equilibrado, elementos de accionamiento
con
- 10 -
ESPAOL
- todas las conexiones elctricas, as como los tornillos y elementos de unin estn apretados y ejecutados segn las disposiciones
En los bornes con estribo (p. ej. segn DIN 46282) los conductores se distribuirn de tal manera que resulte aprox. la
misma altura de conexin en ambos lados. Este tipo de conexin requiere doblar en U uno de los conductores, o usar
un terminal (v. Fig. 3.1). Esto rige igualmente para la conexin del conductor de proteccin y para el conductor de puesta
a tierra exterior, de color amarillo y verde (v. Fig. 3.2).
- que el conductor de proteccin se ha fabricado de acuerdo a

las prescripciones
- que todos los dispositivos adicionales (frenos, velocmetro, ventilador externo.) estn en condiciones de prestar servicio
Los terminales elctricos roscados y los bornes de conexin (exceptuando los de las regletas) estn apretados con el par prescrito; vase la fig. 4.
2.5
- que se han tomado las medidas necesarias contra contactos

involuntarios de piezas en movimiento y bajo tensin
- que no se sobrepasa la velocidad lmite nmx (v. placa de caractersticas).
Control de la resistencia del aislamiento
INDICACION. La velocidad lmite nmx es la velocidad de servicio mxima admisible durante cortos perodos. Hay que tener
en cuenta que en este caso el comportamiento empeora respecto al ruido y a las vibraciones del motor y que se acorta el
perodo para el cambio de los rodamientos.
Antes de la primera puesta en marcha, tras largos perodos de

almacenamiento o de parada (aprox. 6 meses) hay que medir la
resistencia del aislamiento de los arrollamientos.
PRECAUCION
Durante la medicin y seguidamente

despus de ella, los bornes a veces
estn sometidos a tensiones peligrosas, por lo que no deben tocarse.
ATENCION
Tras montar los motores se comprobar el perfecto funcionamiento de

los frenos (si existen).
Resistencia del aislamiento

- La resistencia mnima del aislamiento contra masa de un
arrollamiento nuevo, limpio o reparado es de 10 Megaohmios.
Esta lista no es completa. Posiblemente sean necesarias pruebas adicionales.
- En primer lugar se calcula la resistencia del aislamiento crtica Rcrt. Dicho clculo se efecta multiplicando la tensin asignada UN, p. ej. 0,69 kV AC por el factor constante (0,5 Megaohmios/kV):
Medidas de seguridad
Antes de comenzar cualquier trabajo en el motor o en el aparato y,
especialmente, antes de abrir las
cubiertas de las partes activas, debe desconectarse segn las prescripciones. Tener en cuenta los circuitos adicionales o auxiliares que pudieran haber junto con los circuitos principales.
Rcrt= 0,69 kV * 0,5 Megaohmios/kV = 0,345 Megaohmios.

Medicin
La resistencia mnima del aislamiento contra masa de los arrollamientos se mide con 500 V c.c. Al hacerlo, la temperatura de los
arrollamientos ser de 25C 15C.
PRECAUCION
La resistencia crtica del aislamiento a la temperatura de servicio del arrollamiento se mide con 500 V c.c.
Las usuales 5 reglas de seguridad segn, p. ej., DIN VDE

0105 son:
Control
Si en una mquina nueva, limpia o tras un largo perodo de almacenamiento o de paro la resistencia del aislamiento mnima
contra masa del arrollamiento fuese menor de 10 Megaohmios
podra haber un exceso de humedad. En este caso se secarn los
arrollamientos.
- Desconectar
- Asegurar contra la reconexin
- Comprobar si est libre de tensin
- Poner a tierra y cortocircuitar
Tras un largo perodo de funcionamiento la resistencia mnima

del aislamiento puede bajar a la resistencia crtica. Mientras el
valor medido no sea menor que el calculado para la resistencia
crtica la mquina podr seguir funcionando. Si se alcanzara un
valor menor habra que parar inmediatamente la mquina.
- Cubrir o delimitar las partes contiguas que estn bajo tensin.

Solo podrn retirarse estas medidas cuando se hayan
acabado los trabajos de mantenimiento y el motor se haya
montado completamente
Hay que averiguar cul es el motivo y en su caso reparar los arrollamientos o sus partes, limpiarlos o secarlos.
2.6
INDICACION: Debern abrirse de cuando en cuando los taladros

para el agua de condensacin en los motores en los que dichos
agujeros estn tapados (p. ej., grado de proteccin IP55 IP56, v.
placa de caractersticas), para permitir la salida del agua que pudiera haberse acumulado.
Las aberturas para el agua de condensacin siempre debern
situarse en la parte ms baja del motor.
Puesta en servicio
INDICACION: Cuando el par es muy irregular (p. ej., accionamiento de un compresor de mbolo) se fuerza la formacin de
una corriente distorsionada, cuyas oscilaciones armnicas pueden
influenciar indebidamente a la red as como tambin emitir perturbaciones electromagnticas inadmisiblemente altas.
Si la alimentacin es a travs de un convertidor, las oscilaciones armnicas de tensin y corriente de alta frecuencia en las
lneas de alimentacin pueden emitir perturbaciones electromagnticas. Por esta razn se recomienda el uso de conductores blindados.
Cambio de rodamientos, duracin de la grasa,

tipos de grasa
El plazo de duracin de la grasa bajo condiciones normales de
servicio, montaje horizontal del motor, temperatura del medio refrigerante de hasta 40C y con velocidades del motor de
Antes de la puesta en servicio se comprobar si

- se han observado las resistencias mnimas del aislamiento
- 1500/min, es aprox. 40.000 horas de servicio
- el rotor puede girarse sin que roce
- 3000/min, es aprox. 20.000 horas de servicio.
- si el motor est alineado y montado correctamente

- los elementos de accionamiento estn ajustados correctamente
(p. ej., la tensin de la correa en caso de accionamiento por
correa, ...) y que el elemento de accionamiento es el adecuado
para la aplicacin prevista

Siemens AG
Mantenimiento
Independientemente de las horas de servicio, se recomienda renovar la grasa aprox. cada 3 aos debido a su envejecimiento.Por
ello es necesario desmontar los rodamientos, limpiarlos y lubricarlos noc grasa nueva. En la ejecucin con reengrase se han de
observar los datos en la placa de lubricacin.
- 11 -
ESPAOL
Bajo condiciones de servicio especiales, p. ej., montaje vertical,
servicio frecuente a velocidades lmite nmx, con grandes cargas
por vibraciones y choques, as como con muchos servicios con
inversin de marcha, se reducen considerablemente las horas de
servicio indicadas.
Ventiladores de material plstico (BG180M ... 315L)

Cada ventilador de plstico tiene dos lengetas moldeadas que
encajan como fijacin axial en la ranura anular del eje. Antes de
extraer el ventilador, desencajar estas dos lengetas y fijarlas provisionalmente en esta posicin, p. ej., por medio de piezas insertadas. Los ventiladores tienen en el disco portador dos aberturas
para poder pasar el dispositivo de extraccin que se fija en el
disco. En estado de suministro las aberturas an estn cubiertas
de una fina hoja de plstico que se tiene que romper.
Los motores tienen rodamientos radiales rgidos con un disco de

cierre (ejecucin ZC3).
El disco de cierre est colocado en el lado del rodamiento dirigido
hacia la carcasa del motor (estator).
Tanto para calar como para extraer se utilizar siempre el dispositivo adecuado. Son absolutamente inadmisibles los martillazos
para impedir el dano de los rodamientos.
INDICACION: Al cambiar los rodamientos observar la disposicin

del disco de cierre y el juego del rodamiento, ya que en las ejecuciones especiales pueden ser diferentaes a en las estndar.
Estos discos debern resistir temperaturas desde -20C hasta
+150C, p. ej., ser de caucho poliacrlico (ACM).
Tipos de grasa en las mquinas estndar: (Fa. ESSO /UNIREX
N3); la duracin de las grasas y el plazo para el reengrase se
refieren solamente a este tipo de grasa.
Las grasas alternativas deben satisfacer DIN 51825-KL3N. En este
caso se debern acortar los intervalos de engrase en KT > 25 C.
Las grasas especiales se indican en la placa de caractersticas.
Evtese la mezcla de grasas.
Despiezar el motor tanto como sea necesario. Extraer el rodamiento con el dispositivo adecuado (v. Fig. 6). Limpiar de impurezas
al alojamiento. Limpiar o renovar los rodamientos y volverlos a
engrasar.
Llenar a ras los recintos huecos del rodamiento. No se llena de
grasa la tapa o el escudo portacojinetes, para evitar un engrase
excesivo.
Calentar uniformemente los rodamientos a aprox. 80-100C y calarlos. Evitar golpes fuertes (p. ej., con un martillo, ...).
Tambin se renovarn los elementos de junta deteriorados (p. ej.,
los anillos de cierre radial de eje etc.).
Si los anillos de cierre radial del eje no tuvieran muelles, tampoco
se pondrn muelles en los nuevos.
Dispositivo de reengrase
En los motores con dispositivo de reengrase, se observarn las
indicaciones en la placa de caractersticas.
Sellado de juntas
Al montar mquinas con grado de proteccin IP55 o ms (v. placa
de caractersticas), las superficies pulidas entre la carcasa del
motor y los escudos portacojinetes debern hermetizarse con una
pasta obturadora que no se endurece, p. ej., Hylomar, Curil.

Siemens AG
- 12 -
ITALIANO
Se tiene que cuidar que los pasadores encajen adecuadamente
en las estras del eje.
Per il trasporto di gruppi di macchina (ad es. azionamenti,

soffianti supplementari) vanno utilizzati soltanto gli occhielli
ed i perni previsti per il sollevamento. Il sollevamento di un
gruppo di macchine non deve mai avvenire aggianciando la
componente supplementare alla macchina principale.
PERICOLO
Avvertenze generiche
Assicurarsi che la capacit di portata degli apparecchi di sollevamento sia sufficiente.
Per evitare rischi e danni indispensabile attenersi alle

avvertenze ed alle indicazioni contenute nella presente pubblicazione e nelle istruzioni supplementari in allegato (in giallo),
relative alla sicurezza nellimpiego di macchine ed apparecchi
elettrici, come pure quelle contenute in altri stampati attinenti.
E consigliabile reingrassare i cuscinetti se fra la fornitura e la

messa in servizio dei motori in condizioni favorevoli (magazzinaggio in ambienti asciutti, esenti da polvere e vibrazioni), trascorso
un periodo superiore a 3 anni. In condizioni non favorevoli la durata notevolmente pi breve.
Vanno inoltre rispettate le norme ed esigenze nazionali, locali e specifiche dellimpianto.
Eventualmente va controllata la resistenza disolamento degli avvolgimenti, ved. sez. 2.5.
Esecuzioni speciali e varianti costruttive possono discostarsi in particolari tecnici. In caso di eventuali difficolt, si prega
di rivolgersi al costruttore, indicando il tipo e il numero di matricola, oppure di far eseguire i lavori di manutenzione da uno dei
centri di service della Siemens.
2.2
Dopo linstallazione della macchina gli occhielli di sollevamento

avvitati alla carcassa vanno serrati oppure tolti.
Nelle macchine con estremit dalbero verso lalto e verso il
basso (ad es. IMV5, IMV6, ved. fig. 1) si deve fare attenzione che
non possa penetrare acqua nel cuscinetto superiore.
Avvertenza: Fig. 2 ... (Parti di ricambio) , vedi appendice p. 30
1.1
Descrizione
La parte superiore della carcassa morsetti pu essere ruotata

di 4x90 gradi, in caso di una morsettiera a 6 morsetti e di 180 gradi
con una morsettiera a 9 morsetti.
Campo dimpiego
I motori possono essere installati in ambienti polverosi o umidi.

Lisolamento in versione tropicale. Se il deposito o linstallazione
allaperto sono eseguiti regolarmente, non necessario in linea di
massima alcun particolare accorgimento per proteggere i motori
dalle intemperie.
Silenziosit di funzionamento
Per il funzionamento silenzioso ed equilibrato della macchina sono
indispensabili dei fondamenti stabili e condizioni favorevoli
allinstallazione come anche la regolazione corretta del motore e
lequilibratura precisa dellelemento di azionamento.
Livello di pressione acustica delle superfici di misura a 50Hz

(DIN EN 21680 parte 1)
1LG4, 1LG6, 1LG9
ca. 51 a 76 dB(A)
1.2
Per garantire ci, pu risultare necessario eseguire lequilibratura

completa con lelemento di azionamento oppure stabilizzare la
macchina con spessori di lamiera sottili posti sotto i piedini per
provvedere ad eventuali distorsioni.
Costruzione e modo di funzionamento
2.3
I motori 1LG4, 1LG6 e 1LG9 sono in esecuzione di base autoventilati. Inoltre i motori della serie 1LG possono essere anche senza
il proprio ventilatore (per esempio come motori a ventilatori, a
raffreddamento ad un ventilatore speciale montato allestremit
dellalbero), oppure per mezzo di raffreddamento a ventilatori esterni (opzione G17). I motori 1PP4, 1PP6 e 1PP9 hanno ventilazione naturale (senza ventilatore).
Alla fornitura, i rotori sono equilibrati dinamicamente con

mezza chiavetta.
Il tipo di equilibratura segnato allestremit dellalbero (sul lato
dellazionamento sulla fronte dellalbero).
(H = equilibratura con mezza chiavetta)
(F = equilibratura con chiavetta piena esecuzione
speciale)
Per questa ragione un riposizionamento dei piedini sulla carcassa

del motore, p. es. per variare la posizione della cassetta morsetti,
possibile solo con le opzioni K09, K10 e K11. Le forature necessarie ci sono gi fatte e le superfici sono gi lavorate in modo
opportuno.
Considerare il tipo di equilibratura prima del montaggio

dellelemento di azionamento!
Equilibratura con mezza chiavetta
In caso di elementi di azionamento con un rapporto di lunghezza
di lM < 0,8 e con una velocit superiore a 1500 giri/min., pu risultare compromessa la silenzionsit di funzionamento (ved. fig.8).
Per i motori con il freno (per esempio opzione G26) bisogna rispettare anche le istruzioni di servizio del freno.
Eventualmente sar necessaria la riequilibratura, ad es. riducendo la lunghezza della chiavetta TP sporgente dallelemento di azionamento allestremit dellalbero.
PERICOLO
Osservare le misure di protezione
generali contro i contatti accidentali
degli elementi di azionamento.
Le presenti istruzioni sono valide in qualit di un supplemento delle

istruzioni di servizio del tipo di motore corrispondente. Non valgono per lesecuzione EEx e.
Esercizio
Si faccia attenzione che qualunque

operazione sulla macchina venga effettuata solamente in assenza di tensione.
2.1
Se la messa in servizio di un motore avviene senza lelemento

di azionamento, la chiavetta deve essere protetta contro
lespulsione.
Trasporto, deposito
2.4
Il sollevamento di motori con pi occhielli deve avvenire utilizzandoli tutti.
Siemens AG
Allacciamento
La tensione e la frequenza di rete devono coincidere con i dati

riportati sulla targhetta. Sono ammessi scostamenti del 5% della
tensione o della frequenza (per 1ME6 3% della frequenza), in
PERICOLO

Equilibratura, elementi di azionamento
Le operazioni di calettamento e di estrazione degli elementi di trasmissione (disco di accoppiamento, puleggia, ingranaggio, ..) devono essere sempre eseguite con le apposite attrezzature (fig.7).
Nei motori a piedini i piedini fanno corpo con la carcassa per

fusione oppure, in opzione, sono avvitati alla carcassa (opzione
K11/ved. fig. 2).
PERICOLO
Installazione
- 13 -
ITALIANO
- il motore sia montato ed allineato correttamente
quanto essi non causano una riduzione della potenza. Il collegamento e la disposizione dei ponticelli dovranno corrispondere a
quelli indicati dallo schema applicato allinterno della cassetta
morsetti. Si colleghi il conduttore di protezione al morsetto contrassegnato da
- gli elementi di azionamento siano regolati esattamente (per es.

tensione della cinghia in caso di azionamento a cinghia) e siano
adatti alle condizioni dimpiego.
- utti gli allacciamenti elettrici, viti di fissaggio ed elementi di collegamento siano eseguiti correttamente e ben serrati secondo
le istruzioni.
Quando si effettuano i collegamenti con morsetti di serraggio

(per es. secondo DIN 46282 ), si faccia attenzione che i conduttori abbiano lo stesso spessore su entrambi i lati del morsetto. Questo tipo di collegamento richiede quindi che i singoli conduttori vengano ripiegati ad U o allacciati tramite capocorda. (ved. fig. 3.1). Ci vale anche per il conduttore di
protezione ed il conduttore di messa a terra esterno gialloverde (vedi Fig.3.2 ).
- il conduttore di protezione sia in regola

- funzionino eventuali apparecchiature supplementari (freni, contagiri, ventilatore esterno)
- siano attuati tutti i provvedimenti per la protezione contro i contatti accidentali delle parti in movimento o sotto tensione.
- che il limite max. di giri (nmax) non venga superato (vedi targhetta).
Coppie di serraggio ammesse per viti e dadi dei morsetti (ad eccezione di quelli della morsettiera) vedi fig. 4.
2.5
Avvertenza: Il numero max. di giri ammesso solo per un breve

periodo durante il funzionamento. Bisogna tener conto che ci
pu incidere negativamente sul comportamento della macchina
in quanto riguarda le vibrazioni, la rumorosit ed i gli intervalli di
sostituzione dei cuscinetti.
Verifica della resistenza di isolamento
Prima della prima messa in servizio del motore dopo un lungo

periodo di magazzinaggio o di sosta (circa 6 mesi), necessario
determinare la resistenza disolamento
degli avvolgimenti.
ATTENZIONE
PERICOLO
freno (se presente).
Durante e subito dopo la misurazione,

i morsetti sono in parte sotto tensione
pericolosa e non vanno quindi assolutamente toccati!
Questo elenco non pu essere completo. Possono essere

eventualmente necessarie altre prove.
Resistenza disolamento
- La resistenza disolamento minima contro massa di avvolgimenti nuovi, puliti o riparati 10 MegaOhm
- La resistenza critica disolamento Rkrit deve prima essere calcolata. Il calcolo avviene moltiplicando la tensione di taratura
U N, per es. 0,69 kV AC, con il fattore costante (0,5 MegaOhm/
kV).
Manutenzione
PERICOLO
Indicazioni di sicurezza
Prima di iniziare qualsiasi lavoro

sulla macchina e limpianto, in particolare prima di aprire coperture e carcasse di parti in
servizio, bisogna assicurarsi che la macchina sia priva di
tensione. Ci riguarda non solamente i circuiti principali,
ma bisogna tener conto anche dei circuiti ausiliari e supplementari.
R krit = 0,69 kV * 0,5 MegaOhm/kV = 0,345 MegaOhm

Misurazione
La resistenza disolamento minima degli avvolgimenti contro
massa viene misurata con tensione continua di 500V. La temperatura degli avvolgimenti dovrebbe essere 25C 15C.
Vanno rispettate le 5 regole di sicurezza, ad es sec. VDE

01505:
- togliere la tensione
La resistenza critica disolamento va misurata sulla temperatura di servizio degli avvolgimenti, con tensione continua di 500V.
Verifica
Se, nel caso di una macchina nuova , pulita o rimessa a punto che
stata a lungo in maggazino oppure ferma, la resistenza minima
disolamento degli avvolgimenti contro massa minore di 10MegaOhm, lumidit pu esserne la causa. Bisogna quindi asciugare gli
avvolgimenti.
- proteggere il sistema contro la reinserzione

- assicurarsi che la macchina sia priva di tensione
- collegare a terra e cortocircuitare la macchina
- sbarrare o coprire le parti adiacenti che portano tensione.
Le misure di sicurezza sopraindicate devono essere rispettate fino alla portata a termine dei lavori di manutenzione ed alla completa installazione della macchina.
Dopo un lungo periodo di esercizio, la resistenza minima pu

ridursi alla resistenza critica disolamento. Fintanto che il valore
non scende al di sotto di quello della resistenza critica, si pu
continuare ad utilizzare la macchina. Nel momento in cui il valore
scende al di sotto, la macchina deve essere immediatamente disinserita, e bisogna ricercare le cause; eventualmente dovranno
essere rimessi a punto, puliti o asciugati gli avvolgimenti o le sezioni dellavvolgimento.
2.6
Dopo linstallazionee dei motori va

verificato il perfetto funzionamento del
Avvertenza: In caso di macchine in esecuzione a fori chiusi per lo

scarico di condensa (ad es. tipo di protezione IP55 o IP56, ved.
targhetta), i fori per lo scarico di condensa devono essere aperti
da tanto in tanto per scaricare la condensa eventualmente ristagnata.
Messa in servizio
I fori per la condensa devono essere situati sul fondo della macchina.
Avvertenza: In caso che la coppia sia fortemente disuniforme

(ad es. azionamento di compressore a stantuffi), si forma forzatamente una corrente di macchina non sinusoidale, la cui frequenza
di armonica pu avere una influenza non ammissibile sulla rete e
pu essere la causa di disturbi elettromagnetici troppo forti.
Sostituzione dei cuscinetti, durata delluso di grasso, tipi di grasso
Lalimentazione tramite convertitore pu causare disturbi elettromagnetici derivanti dalla corrente o da tensioni con una frequenza di armonica troppo elevata nei conduttori del motore.Si raccomanda perci limpiego di conduttori schermati.
- 3000/min.: ca. 20 000 ore di servizio
La durata delluso di grasso in condizioni di funzionamento normale, cio installazione orizzontale della macchina, temperatura
del refrigerante inferiore a 40C e un no. max. dei giri motore,
- 1500/min.: ca. 40 000 ore di servizio
Indipendentemente dal numero delle ore di servizio comunque
raccomandabile sostituire il grasso al pi tardi dopo 3 anni (per
motivi di invecchiamento). A tale scopo occorre smontare i cuscinetti, lavarli e d ingrassarli con il grasso nuovo. Per le esecuzioni
dove occorre regolarmente aggiungere il grasso, procedere secondo i dati sulla targhetta di grassaggio.
Prima della messa in servizio bisogna verificare che:

- la resistenza disolamento minima sia in regola
- il rotore possa ruotare senza strisciare

Siemens AG
- 14 -
ITALIANO
Ventilatori in materia plastica (BG180M...315L)
Sotto condizioni particolari, ad es. installazione verticale della

macchina, funzionamento frequente al limite dei giri nmax e intense
sollecitazioni da vibrazioni e urti, inversioni frequenti di marcia ecc.,
gli intervalli per la sostituzione dei cuscinetti sono notevolmente
pi brevi (riduzione delle ore di servizio sopraindicate).
I venilatori in plastica hanno due linguette fuse che si incastrano

nella cava dellalbero come fissaggio assiale. Prima di togliere la
ventola, le due linguette devono essere disinnestate (cacciavite) e
mantenute provvisoriamente in questa posizione, per es. per mezzo
di appositi spessori.
I motori sono provvisti nella versione standard di cuscinetti a sfere

della serie 62 oppure allopzione K36 di cuscinetti a sfere
della serie 63 con un coperchio (esecuzione ZC3).
Sulla piastra di sostegno le ventole hanno due aperture per

lestrattore che deve agganciarsi al mozzo. Queste aperture siano
chiuse da un foglio di plastica per il trasporto che deve essere
tolto.
Il disco di tenuta disposto sul lato cuscinetti della carcassa del

motore (statore).
Per lestrazione e lapplicazione deve venir utilizzato un utensile

adatto. Per proteggere i cuscinetti, evitare assolutamente di dare
martellate!
AVVERTENZA: Prima della sostituzione dei cuscinetti bisogna

assicurarsi della posizione del disco di tenuta e del gioco del cuscinetto, poich esistono diversi varianti speciali rispetto
allesecuzione standard.
Occorre verificare che i scatti siano bene posizionati nelle scanalature dellalbero.
Il materiale dei dischi dovrebbe essere resistente a temperature

entro -20C e + 150C, per es. caucci di poliacrilio (ACM).
Tipo di grasso per le macchine standard: UNIREX N3 (ESSO).
La durata delluso di grassi ed intervalli di grassaggio valgono
soltanto per questo tipo di grasso.
Altri tipi di grasso sostituivi devono corrispondere al minimo alle
norme DIN 51825-KL3N. In questo caso occorre ridurre gli intervalli di grassaggio per KT > 25C.
La miscelazione di diversi tipi di grasso va evitata.
Smontare il motore quanto necessario per eseguire i lavori. Estrarre i cuscinetti con un attrezzo adatto (ved. fig. 6) e pulire la
zona di montaggio dei cuscinetti da insudiciamenti.
Pulire i cuscinetti, sostituirli eventualmente ed eseguire la rilubrificazione. Riempire a livello i spazi vuoti dei cuscinetti con grasso.
I copricuscinetti oppure lo scudo non vengono lubrificati per evitare un ingrassaggio eccessivo.
Riscaldare uniformemente i cuscinetti a 80 - 100C e calettarli.
Non dare colpi forti (martellate)! Vanno sostituiti anche eventuali
elementi di tenuta ad usura (ad es. anelli di tenuta, ecc.). Se gli
anelli di tenuta radiali sono installati senza molla, va utilizzato anche il ricambio nuovo senza molla.
Ingrassatore
In caso dei mmotori con ingrassatore, osservare le indicazioni riportati sulla targhetta.
Tenute
Durante lassemblaggio di macchine con un grado di protezione
IP55 o superiore (ved. targhetta), bisogna rendere stagni le giunzioni nude tra la carcassa e gli scudi per mezzo di un mastice
adeguato, non indurente (ad es. Hylomar, Curil).

Siemens AG
- 15 -
SVENSKA
Om motorn efter leveransen mste frvaras i mera n 3 r under
gynnsamma frhllanden (i torrt, damm- och vibrationsfritt utrymme)
innan den tas i drift, s mste rullningslagren fettas in p nytt. Vid
frvaring under ogynnsamma frhllanden reduceras denna tid
avsevrt.
Allmnna anvisningar
Fr undvikande av risker och skador
mste de uppgifter och anvisningar
som ges i denna driftsinstruktion samt
vriga tillhrande driftsinstruktioner stndigt beaktas.
VARNING
Kontrollera lindningens isolationsmotstnd enl. avsnitt 2.5.
Med denna driftsinstruktion medfljer ven en annan instruktion (gul), som innehller kompletterande skerhetsuppgifter
fr elektriska maskiner och apparater. Denna gller allts som
komplettering av alla vriga levererade driftsoch andra instruktioner inkl. sdana som nnu ej levererats.
2.2
Iskruvade lyftglor dras t eller tas bort efter installationen.

Fr motorer som monteras med axeltappen uppt eller nedt (t.ex.
IMV5, IMV6, se Fig. 1) mste man se till att vatten ej kan trnga in
i det vre lagret.
Beakta dessutom alla nationella, lokala och anlggningsspecifika bestmmelser och krav.
Specialversioner och varianter kan avvika i tekniska detaljer.
Ta alltid kontakt med tillverkaren vid eventuella oklarheter och
ange drvid typbeteckning och tillverkningsnummer, eller
lt alla reparationer utfras av en av SIEMENS servicecentraler.
Uttagsldans verdel kan vridas 4x90 grader, nr man anvnder

en anslutningsplint med 6 klmmor och 180 grader nr man anvnder en plint med 9 klmmor.
Vibrationsfri gng
Frutsttningen fr lugn och vibrationsfri gng r dels ett stabilt
fundament, dels ven att motorerna r exakt uppriktade och att
drivdonet r vl balanserat. Man kan t.ex. undvika mekaniska spnningar genom att lgga tunna pltar under ftterna. I vissa fall kan
det bli ndvndigt att rikta hela rotorn tillsammans med drivdonet.
OBS: Fig. 2 ... (Reservdelar) se bilagan p sid. 30
1.1
Beskrivning
Anvndningsomrde
2.3
Motorerna kan installeras i dammig eller fuktig omgivning. Isoleringen r i tropikutfrande. Vid ndamlsenlig lagring eller uppstllning utomhus erfordras normalt inga speciella skyddstgrder
mot vderpverkan p motorerna.
Motorer av standardmodell r dynamiskt balanserade med full

halv kil (fullkil).
Sttet p vilket balanseringen br genomfras r markerad p
axeltappen (p drivanordningens sida - p axelns panna):
(H = balansering med halv kil)
(F = balansering med full dvs hel kil, specialutfrandet)
Se till att det drivdon som monteras r balanserat p samma stt!
Funktionsstt och konstruktion
Motorerna 1LG4, 1LG6 och 1LG9 finns till i grundutfrandet med

egen kylning (flkt). Dessutom kan motorerna i produktionsserien
1 LG vljas ocks utan egen flkt (mjliga varianter som r till
finnandes r exempelvis ventilatormotorerna i vilka kylingen frsiggr med hjlp av en speciell flkt som finns p axeltappen),
eller r de till frfogande ocks i utfrandet med extern flkt (vljbar
variant G17). Motorerna 1PP4, 1PP6 och 1PP9 r motorer som
har sjlvkyling utan flkt.
Balansering med halv kil

P drivdon med en navlngd I som r <0,8 av axeltappens lngd
I M och med varvtal >1500/min kan rotationsstrningar intrffa (se
Fig.8).
Eventuellt kan efterbalansering erfordras, t.ex. genom nedslipning
av den del av kilen TP, som sticker ut ur drivdonet och utver axelns konturlinje.
I fttermotorerna r ftterna pgjutna p motorhuset; de kan vljbart

levereras ocks med fastskruvna ftter (variant K11, jfr avb Nr 2).
Vidta alla allmnt erforderliga tgrder

fr berringsskyddav drivdonen. Om
en motor tas i drift utan drivdon skall
kilen fixeras s att den inte kan kastas ut.
VARNING
Det r mjligt att flytta om ftterna p motorhuset - ngot som kan

bli ndvndigt exempelvis p g av en frndring i klammerns lge i
varianterna K09, K10 och K11. De drtill ndvndiga borringar och
ytor r redan frberedade p det fr en sdan tgrd bstgnade
stt. I motorerna med egna bromsar (exempelvis variant G26) br
den respektiva bromsgngens driftsinstruktion respekteras!
2.4
Drift
VARNING
2.1
Anslutning och kopplingen av kopplingsblecken jmfrs med kopplingsschemat p insidan av locket till anslutningsldan. Skyddsledare anslutes till denna plint
Vid alla arbeten p motorn mste denna vara spnningsls.
Vid transport br alla lyftglor p motorn utnyttjas.

Vid transport av hela maskinuppsttningar (t.ex. med kuggvxel- eller flktaggregat) fr man bara anvnda befintliga lyftglor eller lyfttappar. Lyft inte maskinuppsttningarna genom att hnga dem i de enskilda maskinerna! Se till
att lyftdonet har erforderlig kapacitet!
VARNING

Vid kontaktklmmor med klmbyglar (t.ex. enl. DIN 46282)

mste ledarna frdelas s att det blir ungefr samma klmhjd p vardera sidan av balken.
Detta slags anslutning krver drfr att en enstaka ledare bjs
i U-form, eller att att man anvnder en kabelsko (Fig. 3.1). Detta
gller ven skyddsledaranslutningen och den externa jordningsledaren (Fig. 3.2).
Transport, frvaring
Siemens AG
Elektrisk anslutning
Ntspnning och ntfrekvens mste stmma verens med de data

som anges p mrkplten. En spnnings- eller frekvensavvikelse
p 5% (vid 1ME6 frekvensavvikelse p 3%) r tillten utan att
effekten behver reduceras.
Dessa anvisningar r giltiga som tillgg till bruksanvisningen fr

den respektiva motortypen. De r inte giltiga vad motorer i genomfrandet EExe betrffar.
Balansering, drivdon
Drivdon (t.ex. kopplingar, remskivor, kugghjul ...) skall dras p och

av med lmpligt verktyg (Fig. 7).
Ljudtrycksniv vid 50 Hz (DIN EN 21 680 del 1)

1LG4, 1LG6, 1LG9
c:a 51 till 76 dB(A)
1.2
Installation
tdragningsmomenten fr elanslutningarnas skruvfrband (gller

ej plintrader), se Fig. 4.
- 16 -
SVENSKA
2.5
Kontroll av isolationsmotstndet
Innan motorn tas i drift frsta gngen samt efter en lngre tids
lagring (c:a 6 mnader) mste man faststlla lindningarnas isolationsmotstnd.
VARNING
Skerhetstgrder
Innan ngot arbete p motorn eller
utrustningen pbrjas, framfr allt
innan skydden ver aktiva delar
ppnas, mste motorn vara skild frn ntet enligt gllande
freskrifter. Uppmrksamma frutom huvudstrmkretsarna ven eventuellt befintliga tillsats- eller hjlpstrmkretsar.
De vanligaste 5 skerhetsreglerna r drvid enligt DIN
VDE 0105:
VARNING
Under och omedelbart efter mtningen ligger det delvis farliga spnningar p klmmorna, som inte fr
berras.
Isolationsmotstnd
- Minsta isolationsmotstnd gentemot jord i nya, rengjorda eller
reparerade lindningar r 10 MegaOhm.
- Det kritiska isolationsmostndet Rkrit berknas frst teoretiskt.
Detta gr man genom att multiplicera mrkspnningen UN, t.ex.
AC 0,69 kV, med konstanta faktorn (0,5 MegaOhm/kV):
- Frnkoppling
- Skra mot terinkoppling
Rkrit = 0,69 kV x 0,5 MegaOhm/kV = 0,345 MegaOhm
- Faststll spnningslshet
Mtning
Ledningarnas minsta isolationsmotstnd gentemot jord mts med
likspnning 500 V. Drvid skall lindningarnas temperatur vara 25C
15C.
- Jorda och kortslut

- Tck ver eller sprra av intilliggande delar som fortfarande
str under spnning
Ovannmnda tgrder fr inte terstllas frrn underhllsarbetena r avslutade och motorn r fullstndigt monterad.
Det kritiska isolationsmotstndet skall mtas med 500 V likspnning nr lindningarna har driftstemperatur.
Kontroll
Om lindningarna i en ny, just rengjord eller reparerad motor som
legat i lager eller sttt stilla under en lngre tid har ett minsta isolationsmotstnd gentemot jord som r mindre n 10 MegaOhm,
s kan det bero p fukt. D mste lindningarna torkas.
OBS: Stngda kondensvattenppningar skall d och d ppnas

fr att det eventuellt samlade kondensvattnet kan tappas ut.
Kondensvattenppningarna skall alltid anordnas lngst ned p
motorn.
Efter en lngre tids driftsuppehll kan minsta isolationsmotstndet sjunka ner till det kritiska isolationsmotstndet. S lnge det
uppmtta vrdet fr det kritiska isolationsmotstndet inte underskrider det berknade vrdet, kan motorn fortfarande hllas i drift.
Om detta vrde underskrids mste motorn omedelbart stoppas.
Lagerbyte, smrjmaterialets livslngd, fettsorter

Smrjmaterialets livslngd r under normala driftsfrhllanden,
vgrt motorinstallation, kylmedelstemperatur max 40C och fr
motorvarvtalet
Faststll orsaken till detta. Eventuellt kan det bli ndvndigt att
reparera, rengra eller torka ut lindningar eller lindningsdelar.
2.6
- 1500/min c:a 40 000 driftstimmar

- 3000/min c:a 20 000 driftstimmar
Idrifttagning
Oberoende av antalet driftstimmar br fettet bytes vart 3:e r p g

av ldrandet. Fr detta ndaml r det ndvndigt att demontera
lager, tvtta dem upp och smrja dem med nytt fett. Ifall den respektiva maskinkonstruktion gr genomgende tillggssmrjning
mjlig, r det ndvndigt att ta hnsyn till uppgifter som finns p
smrjningstabellen.
OBS: Vid starkt varierande vridmoment (t.ex. drivning av en

kolvkompressor) uppstr en icke-sinusformad motorstrm, vars
vertoner kan medfra en otillten pverkan p ntet och alstra
otilltet stora elektromagnetiska strningar.
Vid matning med omriktare kan hgfrekventa strm- och spnningsvertoner i ledningarna till motorn medfra elektromagnetiska strningar. Drfr rekommenderas skrmade ledningar.
Vid speciella driftsfrhllanden - t ex lodrt motorinstallation, ofta

frekommande krning vid maximivarvtalet nMAX, stora vibrationseller sttbelastningar, ofta frekommande reverserande drift- reduceras ovannmnda intervall avsevrt.
Kontrollera fre idrifttagningen att

- minsta isolationsmotstnden ej verskrids,
Motorerna r standardvis utrustade med radiala kullager (sprkullager) serien 62..., eller i vljbar variant K36 r det radialkullager
serien 63.. med en tckbricka som finns till (genomfrandet ZC3).
- rotorn kan vridas runt utan att skrapa emot ngonstans

- motorn r korrekt monterad och riktad
Tckbrickan r placerad p den lagersidan som r vnd mot motorhuset (statorn).
- drivdonen r rtt instllda (t.ex. remspnningen vid remdrift) och

lmpade fr avsedd anvndning
OBS: Ge akt p tckbrickans placering och p lagerns glapprum

vid lagerbyte, eftersom det finns ngra specialutfranden som kan
ha annat arrangemang.
- alla elektriska anslutningar, skruvfrband och frbindelseelement

r tdragna och utfrda enligt freskrift
- skyddsledare resp. skyddsjordning utfrts korrekt
Fettsorter fr standardmotorer (firma ESSO/UNIREX N3): smrjmaterialets livslngd ocn tillggssmrjningens (eftersmrjmningens) frister r giltiga bara fr den hr fettsorten. Eventuella ersttningsfett mste uppfylla tminstone kraven som nmnas i DIN
51825-KL3N. I detta tillflle br smrjningens frister vid KT ver
25C frkortas. Speciella fettsorter r citerade p smrjningens
versiktliga tabell (skylt).
Blanda inte olika fettsorter!
- eventuellt frekommande hjlp- tillstsanordningar (broms, varvmtare, frmmande flkt) r funktionsdugliga

- berringsskydd har ordnats fr rrliga och spnningfrande detaljer
- maximivarvtalet nmax (se mrkskylten), ej verskrids
OBS: Maximivarvtalet nmax r det hgsta kortvariga varvtal som
tillts. Kom ihg att detta frsmrar motorns buller- och vibrationsegenskaper och reducerar lagerbytesintervallet.
VIKTIGT
Ta isr motorn i den mn det behvs. Dra av rullningslagren med

lmpligt verktyg (se Fig. 6). Rengr lagerstllet frn froreningar.
Rengr eller byt ut rullningslagren och fetta in dem p nytt.
Kontrollera att bromsen (om sdan

frekommer) fungerar ordentligt nr
motorerna har monterats.
Fyll lagrens fettutrymmen upp till kanten! Lagerlock resp. lagerskld fr ingen fettfyllning, s att verfettning undviks.
Vrm upp lagren likformigt till ca. 80-100C. Undvik hrda slag
(t.ex. med hammare).
Denna upprkning kan inte vara fullstndig. Ytterligare kontroller kan erfordras.

Siemens AG
Underhll
- 17 -
SVENSKA
Ev. nedslitna ttningar (t.ex. radialttningsring) skall ocks bytas
ut. Om radialttningsringar utan fjdrar r monterade, s fr inte
heller den nya ringen vara frsedd med fjder
Eftersmrjningsanordning
Nrsomhelst speciella smrjfett r ndvndiga, finns det anfrd
p smrjregimens skylt.
Inredning som tjner eftersmrjningen.
I motorerna som har en inredning fr eftersmrjning br uppgifter
som str p smrjningssylten respekteras.
Fogttning.
Nr man stter ihop maskiner i kapslingsklass IP55 eller hgre (se
mrkskylten), s mste de blanka monteringsytorna mellan motorhuset och lagerskldarna ttas med en lmplig inte hrdnande
ttningsmass (t ex Hylomar, Curil).
Plastflkt (BG 180M - 315L)
Plastflktar har tv pgjutna tungor, som snpper in i spret i axeln och fixerar flkten. Innan flkten dras av mste bda tungorna
frigras (skruvmejsel) och provisoriskt hllas kvar i detta lge, t ex
under anvndning av inskjutna mellanbrickor. Skivan som hller
fast flkthjulen r frsedd med tv hl, genom vilka man kan stta
en avdragare mot navet; avdragaren fixeras p skivan. Vid leveransen brukar dessa hl vara frseglade med en tunn plasthinna,
som d mste brytas.
Anvnd alltid lmpligt verktyg vid av- och pdragning. Sl aldrig
med hammaren; hammarslag br undgs med hnsyn til lagerns
beskydd. Det r ndvndigt att klinkor (tungor) riktigt smller igen
i spren p axeln.

Siemens AG
- 18 -
ESKY
Valiv loiska je teba znova namazat, resp. vymnit pouze v ppad, e doba od dodvky do uveden motoru do provozu pi vhodnch podmnkch (skladovn v suchch prostorech bez prachu
a vibrac) je del ne ti roky. Pi nevhodnch podmnkch se tato
doba podstatn zkracuje. V danm ppad je teba pezkouet
izolan odpor vinut, viz odst. 2.5.
Veobecn
Je teba dbt daj a pokyn ve
vech dodvanch provoznch
i ostatnch nvodech. To je nezbytn nutn pro zabrnn rizika razu a pokozen!
UPOZORNN
Dodatkov informace bezpenosti prce (lut) jsou piloeny

a obsahuj doplujc daje k bezpenosti u elektrickch stroj.
Tyto bezpenostn informace jsou tedy doplnnm k dalm dodvanm provoznm a ostatnm nvodm.
2.2
Naroubovan zvsn oka je teba po instalaci dothnout anebo

odroubovat!
Dle je teba brt na vdom veker platn nrodn, mstn

a jin specifick ustanoven a poadavky.
U motor s koncem hdele nahoru nebo dol (nap. IMV5, IMV6 viz obr. 1) je teba zajistit, aby do hornho loiska nemohla vniknout voda.
Zvltn proveden a konstrukn modifikace se mohou liit

v technickch detailech. V ppad nejasnost se v kadm ppad doporuuje obrtit na vrobce s udnm typovho oznaen a vrobnho sla, nebo veker kony drby penechat servisnmu stedisku SIEMENS.
Svorkovnicov kryt u svorkov desky se 6 pipojovacmi svorkami

se me otoit o 4x 90o a u svorkov desky s 9 pipojovacmi
svorkami o 180o .
Klidn chod
Stabiln podklad nebo podmnky vestavby, pesn vyrovnn motor a tak dobe vyven penosov len, to jsou pedpoklady
pro klidn chod bez vibrac. Napklad pod patky je teba podloit
tenk plechy a tm zabrnit namhn motor pnutm nebo v danm ppad je nutn provst kompletn vyven rotoru s penosovm lenem.
POZNMKA: obr. 2 (nhradn dly) viz dodatek na stran 30.
1.
Popis
1.1
Rozsah pouit
Motory je mon instalovat v pranm nebo vlhkm prosted. Izolace je v tropickm proveden. Pi pimenm skladovn nebo
odborn instalaci na otevenm prostranstv nen teba za normlnch okolnost pijmat dn zvltn opaten na ochranu motor
proti povtrnostnm vlivm.
2.3
Standardn jsou rotory vyveny s polovinou pera.

Zpsob vyven je vyznaen na eln stn konce hdele (na
stran pohonu):
(H = vyven s polovinou pera)
(F = vyven s celm perem - zvltn proveden)
Konstrukn uspodn a provozn reim
Pi monti penosovch len je teba dbt na pslun

druh vyven!
Motory 1LG4, 1LG6 a 1LG9 maj v zkladnm proveden vlastn

chlazen ventiltorem. Motory 1LG. je mon dodvat bez vlastnho ventiltoru jako motory pro pohon ventiltor, kter je nasazen
na konci hdele motoru, nebo s cizm chlazenm (opce G17). Motory 1PP4, 1PP6 a 1PP9 jsou motory s vlastnm chlazenm bez
ventiltoru.
Vyven s polovinou pera

U penosovch len s pomrem dlky nboje l k dlce konce
hdele IM < 0,8 a pi potu otek > 1500/min se mohou projevit
poruchy klidnho chodu (viz. obr. 8). V danm ppad je teba
provst vyven, nap. odstranit st pera TP, penvajcho pes
obrys hdele.
U motor jsou patky nality pmo na koste statoru, motory lze

dodvat s naroubovanmi patkami (opce K11/viz obr. 2). Zmna
upevnn patek na koste motoru, nap. z dvod zmny polohy
svorkovnicov skn, je mon u opce K09, K10 a K11. K tomuto
elu potebn vrtn a plochy jsou ji odpovdajcm zpsobem
opracovny.
Je teba dbt veobecnch opaten

na ochranu ped dotykem penosovch len. Je-li motor uvdn do
chodu bez penosovho lenu, pak je teba pero zajistit proti
vymrtn.
UPOZORNN
U motor s brzdou (nap. opce G26) je teba navc vzt do vahy

provozn nvod brzdy!
2.4
Tyto pokyny plat jako doplkov k provoznmu nvodu pslunho typu motoru. Neplat pro motory v proveden EEx e.
2.
2.1
Veker prce na zazen je mon

provdt pouze bez napt.
ku
Pi transportu je teba vyuvat veker zvsn oka na motoru.

Pro pepravu strojovch souprav
(nap. soupravy s pevodovkou, vvvou apod.) je teba pouvat pouze
k tomuto elu uren zvsn oka, resp. epy! Soustroj se
nesm zvedat zavenm pouze jednoho stroje! Je teba dbt
na dodren nosnosti zvedacho zazen!
UPOZORNN
Siemens AG
U pipojovacch svorek s U-tmeny (nap. podle DIN 46282) je

teba vodie rozdlit tak, aby na obou stranch tmenu byla
stejn vka pipojovanho vodie. Tento zpsob pipojen
tedy vyaduje, aby jednotliv vodie byly zahnuty ve tvaru U
anebo pipojeny pomoc kabelovho oka (viz obr. 3.1). To
plat tak pro pipojen ochrannho vodie a vnj uzemovac vodi (viz obr. 3.2) - zelenolut.
Transport, skladovn

Pipojen
Napt a frekvence st mus souhlasit s daji na vkonnostnm

ttku. Odchylka 5% u napt nebo frekvence (u 1ME6 3% odchylka frekvence) je ppustn jet bez snen vkonu. Pipojen
a uspodn propojek provdt podle schma zapojen, kter se
nachz ve svorkovnicov skni. Ochrann vodi pipojit na svor-
Provoz
UPOZORNN
Vyven, penosov leny
Nasazovn a stahovn penosovch len (spojky, emenice, ozuben kolo) je teba provdt s vhodnm zazenm (obr. 7).
Hladina akustickho tlaku na mench plochch pi 50 Hz

(DIN EN 21 680 st 1)
1LG4, 1LG6, 1LG9,
cca 60 a 76 dB(A)
1.2
Instalace
Utahovac momenty pro roubov spoje elektrickch pipojen pipojen svorkovch desek (krom svorkovch lit) viz obr. 4.
- 19 -
ESKY
2.5
Tento vet neme bt pln a proto jsou rovn nezbytn

dal kontroly.
Pezkouen izolanho odporu
Ped prvnm uvedenm motoru do provozu, po delm skladovn

nebo odstaven (cca 6 msc), se mus zjistit izolan odpor vinut.
UPOZORNN
3.
Bhem men a bezprostedn po

nm je na svorkch sten nebezpen napt a proto se jich nesmte
dotkat.
Bezpenostn opaten
Ped zahjenm prce na motoru
nebo zazen, zvlt pak ped otevenm kryt aktivnch st, se
mus motor pedpisov vypnout. Mimo hlavnch proudovch obvod je teba pitom dbt tak na ppadn vedlej a pomocn proudov okruhy.
VAROVN
Izolan odpor
- Minimln izolan odpor u novho, vyitnho nebo opravenho vinut vi koste in 10 MOhm.
- Nejdve je teba vypotat kritick izolan odpor R krit. Vpoet
se provd vynsobenm jmenovitho napt U N, nap. AC
0,69 kV, s konstantou (0,5 MOhm/kV):
Existuje 5 obvyklch bezpenostnch zsad ve smyslu

nap. DIN VDE 0105:
- vypnout
R krit = 0,69 kV x 0,5 MOhm/kV = 0,345 MOhm
- zajistit proti optovnmu zapnut
Men
Minimln izolan odpor vinut se m proti koste stejnosmrnm naptm 500 V. Pitom teplota vinut je 25o C 15oC.
- zjistit, zda je zazen bez napt

- zkontrolovat uzemnn a propojen na krtko
Kritick izolan odpor je teba mit pi provozn teplot vinut

stejnosmrnm naptm 500 V.
- zakrt nebo pehradit sousedn sti pod naptm

Ve uveden opaten se sm zruit teprve v ppad, kdy
jsou veker servisn kony dokoneny a motor je kompletn smontovn.
Pezkouen
Jestlie u novho, vyitnho nebo opravenho motoru, kter
byl del dobu skladovn nebo odstaven, je minimln izolan odpor vinut proti koste men ne 10 MOhm, pak pinou me bt
vlhkost. Vinut je teba nejdve vysuit.
POZNMKA: Uzaven otvory pro odtok kondenzovan vody se

mus obas otevt, aby se mohla vypustit nashromdn kondenzovan voda.
Po del dob provozu me minimln izolan odpor poklesnout

na hodnotu kritickho izolanho odporu. Pokud namen hodnota nepoklesla pod vypotenou hodnotu kritickho izolanho odporu, sm se motor dle provozovat. Jakmile poklesne pod kritickou hodnotu, mus se motor okamit vypnout.
Otvory pro odtok kondenzovan vody jsou vdy v nejnim mst

motoru!
Vmna loisek, ivotnost maziva, druhy mazacch tuk
Je teba zjistit pinu a v danm ppad vinut nebo jeho sti

nechat opravit, vyistit nebo nechat vyschnout.
2.6
ivotnost maziva in za normlnch provoznch podmnek, pi vodorovn instalaci motoru, teplot chladiva do 40oC a potu otek
motoru
Uveden do provozu
- 1500 ot/min cca. 40.000 provoznch hodin
POZNMKA: V ppad siln nerovnomrnho kroutcho momentu

(nap. pohon pstovho kompresoru) vynucen motorov proud
nem sinusov tvar, piem jeho vy harmonick mohou mt
neppustn vliv na s a tak me zpsobovat neppustn vysok elektromagnetick ruen.
- 3000 ot/min cca. 20.000 provoznch hodin

Nezvisle na provoznch hodinch by se mazac tuk ml z dvod
strnut mnit piblin kad 3 roky. Za tmto elem je teba
loiska demontovat, vymt a namazat novm tukem. U proveden
s domazvnm je teba dbt daj na ttku mazn.
Pi napjen mniem mohou vysokofrekvenn proudy a napt

zpsobit ruen v pvodnch vodich motoru, proto se doporuuje
pouvn odstnnch pvodnch veden.
Za zvltnch provoznch podmnek, nap. svisl instalace motoru,

pi astjm provozu s maximlnm ppustnm potem otek
nMAX, pi velk zti chvnm a rzy a pi ast reverzaci, se ve
uveden poty provoznch hodin podstatn sniuj.
Ped uvedenm do provozu je teba zkontrolovat, zda:

- jsou dodreny hodnoty minimlnho izolanho odporu
Ve standardnm proveden maj motory radiln kulikov loiska

ady 62 ... nebo jako opce K36 radiln kulikov loiska ady 63 ...
s jednm krycm kroukem (proveden ZC3).
- rotorem lze voln pootoit

- motor je dn namontovn a vyrovnn
Kryc krouek je umstn na stran loisek, obrcen ke koste

motoru (stator).
POZNMKA: Pi vmn loisek je teba brt ohled na uspodn krycho krouku a vli loiska, ponvad to se u zvltnch proveden me liit od proveden standardnch!
- penosov leny jsou sprvn usazeny (nap. napnut emene u

emenovho pevodu) a penosov len je vhodn pro dan podmnky pouit
- veker elektrick spoje, upevovac rouby a spojovac prvky
jsou pedpisov pipojeny a dotaeny
- ochrann vodi je dn pipojen
Mazac tuky u standardnch stroj: (Fa. ESSO / UNIREX N3);

ivotnost maziv a lhty pro domazvn plat pouze ve spojen s
tmto druhem maziva.
- ppadn pdavn zazen (brzda, tachogenertor, ciz ventilace) je funkn

- jsou provedena opaten proti dotyku pohyblivch st a dl
pod naptm
Nhradn tuky mus vyhovovat minimln norm DIN 51825-KL3N.

V tomto ppad je teba intervaly mazn u KT >25o C snit.
Zvltn tuky jsou uvedeny na mazacm ttku.
- nejsou pekroeny maximln ppustn otky nmax (viz vkonnostn ttek)
Mchn rznch druh maziv je neppustn!

Motor demontovat v potebnm rozsahu. Valiv loiska stahovat
vhodnm zazenm (viz obr. 6). Z msta loiska odstranit neistoty! Valiv loiska vyistit, resp. vymnit a znova namazat.
POZNMKA: Maximln ppustn otky nmax jsou nejvy krtkodob ppustn provozn otky. Je teba vzt do vahy, e se
pitom zhoruje hlunost a vibrace motoru a tak sniuje ivotnost loisek.
UPOZORNN
Siemens AG
Voln prostor valivch loisek zcela naplnit mazacm tukem. Loiskov vko resp. loiskov tt zstane bez tukov npln, aby
se tak zabrnilo pemazn.
Po namontovn motor je teba

zkontrolovat dokonalou funkci brzdy (v ppad instalace)!

drba
- 20 -
Loiska rovnomrn zaht asi na 80-120o C a nasadit. Nepouvat siln dery (nap. kladivem).
Ppadn opoteben tsnic prvky (nap. tsnn hdele atd.) je
teba rovn vymnit. Jestlie jsou namontovny radiln hdelov tsnic krouky bez pruiny, pak se mus pout tak nhradn
dly bez pruiny.
Zazen pro domazvn
U motor se zazenm pro domazvn je teba dbt daj na
ttku mazn!
Utsnn spr
Pi monti stroj s druhem ochrany IP 55 nebo vym (viz vkonnostn ttek) se mus ist montn plochy mezi kostrou motoru a loiskovm ttem utsnit vhodnou, nikoliv vytvrzovatelnou,
tsnic hmotou (nap. Hylomar, Curil).
Plastov ventiltory (BG180M ... 315L)
Plastov ventiltory maj dva nlitky, kter jako axiln fixace zapadnou do kruhov drky na hdeli. Ped stahovnm ventiltoru
se mus oba nlitky vysunout (roubovkem) a v tto poloze pechodn podret, nap. pomoc vsunutch ploek. Ventiltory maj
v nboji dva otvory pro nasunut stahovacho ppravku, kter se
na nboj pipevn.
Otvory jsou pi dodvce uzaveny tenkou vrstvou z uml hmoty,
kter se pak mus prorazit.
Pro stahovn a tak pro nasazovn se mus zsadn pouvat
vhodn ppravek. Pitom je teba bezpodmnen zabrnit derm kladiva, aby se nepokodila loiska.
Je teba dbt na sprvn zaskoen zpadek do drky na hdeli.

Siemens AG
- 21 -
2.1

. ,
!
(.
, .)

!
!
!

() .
, .
,

.

,
(
) .

.
, . 2.5.

,
.

.

,
,
SIEMENS.
2.2
: . 2 ( )
30.
(. IMV5, IMV6
. 1) ,
.
1.
1.1
6 4 90
9 180 .

,

.

.
.
.

.

50
(DIN EN 21 680 1)
1LG4, 1LG6, 1LG9,
1.2
2.3
(,
, )
(. 7).
60 70 ()
1LG4, 1LG6 1LG9

.
1LG
,
,
( G17). 1PP4, 1PP6 1PP9
.

( );
.
(
11/ . 2).
, .
, 09, 10 11.
.

l
l < 0,8 > 1500/
M
( . 8).
, .
, .
(. G26)
!

. ,
,
.
(H = )
(F = )

!

.
.
2.
2.4.
Siemens AG

. 5%
( 1ME6 3% )
.

- 22 -

, .

, :

U (. DIN 46282)
,
. ,
,
U
( . 3.1).

( . 3.2)
.

(.
)

,

(
) . 4.
(,
, )

2.5.
nmax
( )
: nmax
.
,

.
,
( 6
) .

, .

- ,
10 .

( )!
,
.

Rkrit .
UN, . AC 0,69 ,
(0,5 /).
3.
R = 0,69 0,5 / = 0,345

,

,
.
.

500 .
25 15 .

500 .
, ,
,
,
10 ,
. .
5
. DIN VDE 0105:

.

,
.
, .

,

,
.

, .
:

,

.
2.6
:
(. )
,

.

!
, ,
,

,
40

,
.

Siemens AG
1500 / 40.000
3000 / 20.000

.
- 23 -

,
.
.
, .
,
n ,
max

.

62
36 63
( ZC3).

55 (
)

, (.
Hylomar, Curil).
(BG180M 315L)
,
.
,
() , .
.
,
.
,
().
:
,

!
,
.

. , .
: (. ESSO / UNIREX N3);

.
DIN 51825KL3N.
>25 .
,
.
.
!
.
( . 6).
! ,
. .

. ,
,
.
80
120 . (.
).
(.
.) . ,

, .

Siemens AG
- 24 -
DEUTSCH / ENGLISH / FRANAIS / ESPAOL / ITALIANO / SVENSKA / ESKY /
BG 180M . . . 250M
1LG4
1LG6
Fig. 2 +
Siemens AG
- 25 -
BG 280S . . . 315L
1LG4
1LG6
BG 280S - 315L
Fig. 3 +
Siemens AG
- 26 -
gk 330
gt 320
Normteile sind nach Abmessung, Werkstoff und Oberflche

im freien Handel zu beziehen.
commerce daprs leurs dimensions, le matriau et ltat

de surface.
Normerade detaljer kan erhllas i ppna handeln, och skall

specificeras betrffande storlek, material och ytbehandling.
Standard commercially available parts are to be purchased

in accordance with the specified dimensions, material and
surface finish.
Las piezas estndar se comprarn en comercios del ramo

segn las dimensiones, material y superficie especificados.
Normovan dly lze podle rozmr, materilu a povrchu

zakoupit voln v obchodech.
Le parti standard sono reperibili sul mercato secondo le

dimensioni, il materiale e la finitura della superficie.

, .
1.49
1.66
4.11
6.30
6.25
DIN 912
ISO 4762
3.38
DIN 6885
5.53
DIN 936
ISO 4035
1.50
4.39
5.79
5.90
5.92
5.98
5.31
DIN 931
ISO 4014
5.66
5.67
EN 50262
Les pices normalises peuvent tre obtenues dans le

4.38
5.91
5.21
5.78
5.93
5.32
DIN 128
3.02
3.03
DIN 471
6.02
DIN 472
4.04
DIN 580
4.40
5.36
DIN 7985
ISO 7048
DIN 125
Fig. 2a
Siemens AG
DIN 933
ISO 4017
1.60
6.10
DIN 625
Lagertyp:
Type of bearing:
Type de roulement:
Tipo de cojinete:
Tipo di cuscinetto:
Lagertyp:
Typ loiska:
:
- 27 -
gk 430
gt 420


de surface.


surface finish.




, .
1.49
1.66
4.11
6.30
6.25
DIN 912
ISO 4762
3.38
DIN 6885
5.53
DIN 936
ISO 4035
1.50
4.39
5.79
5.90
5.92
5.98
5.31
DIN 931
ISO 4014
5.66
5.67
EN 50262

4.38
5.91
5.21
5.78
5.93
5.32
DIN 128
3.02
3.03
DIN 471
6.02
DIN 472
4.04
DIN 580
4.40
5.36
DIN 7985
ISO 7048
DIN 125
Fig. 2b
Siemens AG
DIN 933
ISO 4017
1.60
6.10
DIN 625
Lagertyp:
Type of bearing:
Type de roulement:
Tipo de cojinete:
Tipo di cuscinetto:
Lagertyp:
Typ loiska:
:
- 28 -
gk 431
gt 421


de surface.


surface finish.




, .
1.49
1.66
4.11
6.30
6.25
DIN 912
ISO 4762
3.38
DIN 6885
5.53
DIN 936
ISO 4035
1.50
4.39
5.79
5.90
5.92
5.98
5.31
DIN 931
ISO 4014
5.66
5.67
EN 50262

4.38
5.91
5.21
5.78
5.93
5.32
DIN 128
3.02
3.03
DIN 471
6.02
DIN 472
4.04
DIN 580
4.40
5.36
DIN 7985
ISO 7048
DIN 125
Fig. 2c
Siemens AG
DIN 933
ISO 4017
1.60
6.10
DIN 625
Lagertyp:
Type of bearing:
Type de roulement:
Tipo de cojinete:
Tipo di cuscinetto:
Lagertyp:
Typ loiska:
:
- 29 -
gt 520
gt 540
- for cable arrangements without lugs only terminal board

(5.10) from gt 540 possible
- fr Kabelschuhlosen Anschlu! nur Klemmenbrett (5.10)
aus gt 540 zulssig


de surface.


surface finish.




, .
1.49
1.66
4.11
6.30
6.25
DIN 912
ISO 4762
3.38
DIN 6885
5.53
DIN 936
ISO 4035
1.50
4.39
5.79
5.90
5.92
5.98
5.31
DIN 931
ISO 4014
5.66
5.67
EN 50262

4.38
5.91
5.21
5.78
5.93
5.32
DIN 128
3.02
3.03
DIN 471
6.02
DIN 472
DIN 7985
ISO 7048
4.04
DIN 580
4.40
5.36
DIN 125
Fig. 2d
Siemens AG
DIN 933
ISO 4017
1.60
6.10
DIN 625
Lagertyp:
Type of bearing:
Type de roulement:
Tipo de cojinete:
Tipo di cuscinetto:
Lagertyp:
Typ loiska:
:
- 30 -
gt 620
gt 640
- for cable arrangements without lugs only terminal board

(5.10) from gt 640 possible
- fr Kabelschuhlosen Anschlu! nur Klemmenbrett (5.10)
aus gt 640 zulssig


de surface.


surface finish.




, .
1.49
1.66
4.11
6.30
6.25
DIN 912
ISO 4762
3.38
DIN 6885
5.53
DIN 936
ISO 4035
1.50
4.39
5.79
5.90
5.92
5.98
5.31
DIN 931
ISO 4014
5.66
5.67
EN 50262

4.38
5.91
5.21
5.78
5.93
5.32
3.02
6.02
4.04
DIN 128
DIN 471
DIN 472
DIN 580
4.40
5.36
DIN 7985
ISO 7048
DIN 125
Fig. 2c
Siemens AG
DIN 933
ISO 4017
1.60
6.10
DIN 625
Lagertyp:
Type of bearing:
Type de roulement:
Tipo de cojinete:
Tipo di cuscinetto:
Lagertyp:
Typ loiska:
:
- 31 -

Anschliebare Querschnitt je nach Klemmengre (ggf. reduziert durch Gre der Leitungseinfhrungen)
Conductor cross-sections connectable to the various terminals (may be reduced by size of cable entries)
Sections raccordables suivant la taille de la borne (rduction ventuelle par la taille des entres de cbles)
Seccin conectable segn tamao del borne (en caso dado, ms pequea debido al tamao de las entradas de linea)
Diamentri dei collegamenti a sec. delle misure dei morsetti (eventualmente sono ridotte le dimensioni delle aperture per i conduttori)
Anslutningsbara ledarareor fr olika klmstorlekar (ev. reducerat med hnsyn till genomfringens storlek)
Pipojovac prez podle velikosti svorek (v danm ppad omezen velikost prchodek veden).
( ).
... 25 mm2
... 10 mm2
... 25 mm2
Bei Anschlu mit DIN- Kabelschuh ist dieser nach unten abzuwinkeln!
Anschlu eines einzelnen Leiters

mit Klemmbgel.
Anschlu von zwei etwa gleich

dicken Leitern mit Klemmbgel.
Bei Anschlu mit DIN- Kabelschuh unter uerem Erdungswinkel.
Bei Anschul mit DIN- Kabelschuh.
If connections are made with DIN

cable lugs, band the cable lugs
downwards.
Connecting a single conductor

with a terminal clip.
Connecting two conductors of almost equal thidcness with a terminal clip.
If connectionsare made with DIN

cable lugs, under the outer earthing engle.
If connections are made with DIN

cable lugs.
Lorsque le raccordement est ralis par cosses DIN, cellesci doivent tre pliss vors le bas.
Raccordement dun seul conducteur une Borne trier.
Deux conducteurs de diamtre

peu pr quivalents, raccords
une borne trier.
Lorsque le raccordement est ralis par cosses DIN, une querre extrieure de mise la terre.
Lorsque le raccordement est ralis par cosses DIN.
Si la conexin se efecta con terminales para cables DIN, habr

que doblarlos hacia abajo.
Conexin de un solo conductor

con un estribo.
Conexin de dos conductores de

dimetro aproximadamente igual,
con un estribo.
Si la conexin se efecta con terminales para cables DIN, bajo el

angular exterior de puesta a tierra.
Si la conexin se efecta con terminales para cables DIN.
Nel collegamento con capocorda

conforme alle norme DIN, questo
va piegato verso il basso.
Allacciamento di ogni singolo conduttore con morsetto di serraggio.
Allacciamento di due conduttori di

stesso o pressocch indentico spessore con morsetto di serraggio.

conforme alle norme DIN, sotto
angolare di messa a terra esterno.

conforme alle norme DIN.
Vid anslutning med kabelsko enl.

DIN skall denna bockas nedt.
Anslutning av en enkelledare med

klmbygel.
Anslutning av tv ungefr lika

tjocka ledare med klmbygel.

DIN under extern jordningsvinkel.

DIN.
Pipojen pomoc kabelovho oka

DIN je teba je ohnout smrem
dol.
Pipojen jednotlivho vodie

U-tmenem.
Pipojen dvou vodi stejnho

prezu s U-tmenem.
Pipojen kabelovm okem DIN

pod vnjm uzemovacm tmenem.
Pipojen kabelovm okem DIN.

DIN
.

U.

U.

DIN
.

DIN.
... 25 mm2
DIN 46 234
Fig. 3.1
Fig. 3.2
Anziehdrehmomente fr Schraubenverbindungen der elektrischen Anschlsse - Klemmenbrettanschlsse (auer Klemmenleisten)

Tightening torques for screwed electrical connections - terminal board connections (except for terminal strips)
Couples de serrages des bornes de la plaque bornes (ne concerne pas las borniers)
Pares de apriete para uniones atornilladas de las conexiones elctricas en la placa de bornes (exceptuando las regletas de bornes).
Coppie di serraggio per le viti di attacco di collegamenti elettrici / dei portamorsetti (escluse morsettiere)
tdragningsmoment fr de elektriska anslutningarnas skruvfrband (utom p kontaktplintar)
Utahovac momenty pro roubov spoje elektrickch pipojen - pipojen na svorkovch deskch (mimo svorkovnicov lity).
(
).
Gewinde- / Thread- / du filetage
de la rosca / Diametro del filetto
Gngdimeter / Zvit /
Anziehdrehmoment
Tightening torque
Couple de serrage
Par de apriete
Coppia di serraggio
tdragningsmoment
Utahovac moment

Fig. 4
M5
M6
M8
M10
M12
M16
min
0,8
1,8
2,7
5,5
14
27
max
1,2
2,5
13
20
40
Die obigen Anziehdrehmomente gelten soweit keine anderen Werte angegeben sind!
The above values of tightening torque are applicable unless alternative values are given elsewhere.
Les couples de serrage indiqus ci-dessus sont valables pour autant quaucune valeur spcifique ne soit donne.
Estos pares de apriete rigen mientras no se indiquen otros.
Le coppie di serraggio indicate qui di sopra sono valide se non sono indicati altri valori.
Ovanstende tdragningsmoment gller om ej andra vrden angivits!
Ve uveden utahovac momenty plat, pokud nejsou uvedeny jin hodnoty.
, .

Siemens AG
Nm
M4
- 32 -

Lagerwechsel / Changing bearings / Remplacement des roulements / Cambio de cojinetes
Sostituzione del cuscinetto / Lagerbyte / Vmna loiska /
Fig. 6
Zwischenscheibe (Schutz der Zentrierung im Wellenende)

Spacer washer (to protect centring bore in shaft end)
Rondelle (protection du centrage en bout darbre)
Disco intermedio (protege el centrado en el extremo del eje)
Spessore (protezione delle centratura nullestremit dalbero)
Distansbricka (skydd av centreringen I axeltappen)
Vloen podloka (ochrana stedcho dlku na konci hdele)
( )
Auf- und Abziehen von Abtriebselementen / Pressing on and pulling off drive elements / Emmanchement et extraction dorganes
de transmission / Calado y extraccin de elementos de accionamiento / Calettamento ed estrazione degli elementi di azionamento
/ P- och avdragning av drivdon / Nasazovn a stahovn penosovch len /
Zwischenscheibe (Schutz der Zentrierung im Wellenende)
Spacer washer (to protect centring bore in shaft end)
Rondelle (protection du centrage en bout darbre)
Disco intermedio (protege el centrado en el extremo del eje)
Spessore (protezione della centratura nullestremit dalbero)
Distansbricka (skydd av centreringen I axeltappen)
Vloen podloka (ochrana stedcho dlku na konci hdele)
( )
Zum Aufziehen von Abtriebselementen (Kupplung, Zahnrad, Riemenscheibe usw. ), Gewinde im Wellenende benutzen und - sofern mglich -Abtriebselemente nach Bedarf erwrmen.
Zum Abziehen geeignete Vorrichtung verwenden. Es drfen beim Auf- und Abziehen keine Schlge (z.B. mit Hammer oder hnlichem) oder grere als die laut Katalog zulssigen radialen
oder axialen Krfte ber das Wellenende auf die Motorlager bertragen werden.
Use the tapped hole provided in the end of the shaft for fitting drive components such as couplings, gearwheels, belt pulleys, etc. and, if possible, heat the components as necessary. Use
a suitable puller tool for removing the components. Do not strike the components, e.g. with a hammer or similar tool, when fitting or removing them and do not exert more than the maximum
value of radial or axial force - according to the catalog - transmitted to the motor bearings through the shaft extension.
Pour monter les organes de transmission (accouplements, roues dentes, poulies courroie, etc.), utiliser le taraudage du bout darbre. Au besoin et lorsque cela est possible, chauffer les
organes de transmission. Pour le dmontage, utiliser un dispositif appropri. Aucun coup (par ex. marteau) suprieur aux efforts axiaux et radiaux admissibles mentionns au catalogue
ne doit tre transmis par larbre aux roulements en cours de montage ou de dmontage.
Para calar Ios elementos de accionamiento (acoplamientos, rueda dentada, polea, etc.) utilizar la rosca en el extremo del eje y - siempre que sea posible - calentar convenientemente
dichos elementos. Utilizar el dispositivo adecuado para la extraccin. Durante las operaciones de calado o extraccin no golpear (p. ej. con martillo o similar) ni ejercer sobre los cojinetes
del motor a travs del extremo del eje fuerzas axiales o radiales superiores a las admisibles segn catlogo.
Per calettare gli elementi di azionamento (giunti, ruote dentate, pulegge, ecc.), utilizzare il foro filettato nellestremit dalbero e, se possibile, riscaldare gli elementi di azionamento. Per
lestrazione vanno adoperati attrezzi adatti. Sono da evitare colpi o martellate, e forze radiali o assiali trasmesse dallestremit dalbero ai cuscinetti che siano maggiori di quelle consentite
sec. il catalogo.
Anvnd axeltappens gnga vid pdragning av drivdon (koppling, kugghjul, remskiva etc) och vrm om mjligt upp drivdonen om s behvs. Anvnd lmpliga verktyg fr avdragningen.
Ngra slag (t.ex. med hammare e.dyl.) fr aldrig frekomma vid p- och avdragning, och radiella och axiella krafter som r strre n de som anges i katalogen fr inte verfras till
motorlagren via axeltappen.
Pro nasazovn penosovch len (spojka, ozuben kolo, emenice atd.) pouvat zvit na konci hdele a - pokud je to mon - penosov leny podle poteby naht. Pro stahovn
pouvat vhodn ppravek. Pi nasazovn a stahovn se nesm pouvat dn dery (nap. kladivem apod.) nebo vt radiln nebo axiln sly, ne jsou ppustn podle katalogu, kter
se penej pes konec hdele na loiska motoru.
(, , .) .
. ( .)
, .
Fig. 7
Auswuchtung mit halber Pafeder / Balancing with half featherkey
Equilibrage avec demi-clavette / Equilibrado con media chaveta
Equilibratura con mezza chiavetta / Balansering med halv kil
Vyven s polovinou pera /
Nabenlnge I / Hub length I / Longueur du moyeu I / Longitud del cubo I

Lunghezza mozzo I / Navlngd I / Dlka nboje l / l
Herausragender Teil der Pafeder T P

Protruding section of featherkey TP
Partie saillante TP de la clavette
Parte saliente de la chaveta TP
Parte sporgente della chiavetta Tp
Nedslipning av den del av kilen TP
Penvajc st zalcovanho pera TP

Fig. 8
Siemens AG
Lnge des Wellenendes IM / Length of shaft I M / Longueur du bout darbre IM / Longitud del extremo del eje IM
Lunghezza IM dellestremit dalbero / Axeltappens lngd IM / Dlka konce hdele lM / lM
- 33 -
ANHANG / APPENDIX / APPENDICE / ANEXO / APPENDICE / BILAGA / DODATEK /

DEUTSCH
ENGLISH
FRANAIS
ESPAOL
Ersatzteile, vom Werk lieferbar

(s. Bestellbeispiel)
Spare parts, available from the works

(see specimen orders)
Pices de rechange, livrables par lusine

(voir exemple de oommande)
Piezas de recambio; suministro desde

fbrica (vase ejemplo de pedido).
1.00
.40
.43
.58
.60
.61
.65
.67
.68
.69
Lagerung AS
Lagerschild
Wellendichtring
Federscheibe
Wlzlager
Verschlustopfen
Lagerdeckel
Ausserer Lagerdeckel
Schleuderscheibe
Druckfeder
1.00
.40
.43
.58
.60
.61
.65
.67
.68
.69
Bearing assembly, drive end

Endshield
Shaft sealing ring
Resilient preloading disc
Rolling-contact bearing
Plug
Cover of bearing
Outer bearing cap
Grease slinger
Compression springs
1.00
.40
.43
.58
.60
.61
.65
.67
.68
.69
Palier ct entranement
Flasque-palier
Bague dtanchit
Rondelle lastique
Roulement
Bauchons
Couvercle de palier
Couvercle extrieur de palier
Disque de projection
Ressort de compresson
1.00
.40
.43
.58
.60
.61
.65
.67
.68
.69
Cojinete del LA
Escudo portacojinetes
Retn
Arandela de resorte
Rodamiento
Tapn
Cubierta del cojinete
Tapa exterior del cojinete
Anillo de engrase
Muelles de presin
3.00 Lufer, komplett
3.00 Rotor, complete
3.00 Rotor, complet
3.00 Rotor, completo
4.00
.07
.18
.35
.40
.41
4.00
.07
.18
.35
.40
.41
4.00
.07
.18
.35
.40
.41
Stator, complet
Pied du corps (BG 180 gauche, droit)
Plaque signaltique
Disque
Disque
Borne de mise la terre
5.00
.03
.10
.33
.34
.35
.44
.51
.52
.70
.71
.72
.83
.84
.89
.94
.95
.96
.97
.99
Bote bornes, complte

Joint (torique sur HA 200)
Plaque bornes, complte
Plaquette arrte en rotation
Etrier de serrage
Passe-cble en caoutchone
Partie suprieure de la bote bornes
Ecrou
Barrett droite
Etrier de serrage
Couvercle extrieur de palier
Disque de projection
Joint
Couvercle de la bote bornes
Vis
Vis
Bornier pour circuit auxiliaire
Lardon porteur
tai complet
Tle de contact
4.00 Estator, completo

.07 Pedestal del cuerpo (BG180
izquierdo, derecho)
.18 Placa de caractersticas
.35 Arandela
.40 Disco
.41 Borne de puesta a tierra
6.00
.10
.20
.23
.24
.65
.66
.67
Palier ct oppos lentranement

Roulement
Flasque-palier
Bague dtanchit
Couvercle de palier
Graisseur
Douille en caoutchouc
Tube de graissage
7.00
.04
.40
.41
.49
Ventilation, complte
Ventilateur
Capot du ventilateur
Equerre
Vis
Stnder, komplett
Gehusefu (BG180 - rechts, links)
Leistungsschild
Scheibe
Scheibe
Erdungslasche
Stator, complete
Body footing (BG 180 - left, right)
Rating plate
Disc
Disc
Earthing terminal
5.00 Klemmenkasten, komplett

.03 Dichtung
(BG200 Schnurdichtung)
.10 Klemmenbrett, komplett
.33 Unverdrehbare Unterlage
.34 Klemmbgel
.35 Gummistopfen
.44 Klemmenkasten-Oberteil
.51 Mutter
.52 Schaltbgel
.70 Klemmbgel
.71 Ausserer Lagerdeckel
.72 Schleuderscheibe
.83 Dichtung
.84 Klemmenkasten-Deckel
.89 Schraube
.94 Schraube
.95 Klemme
.96 Tragschiene
.97 Strebe komplett
.99 Kontaktblech
5.00 Terminal box, complete

.03 Gasket (frame sizes 200: cord-type
gasket)
.10 Terminal board, complete
.33 Not-twist shim
.34 Terminal clip
.35 Rubber plug
.44 Upper part of terminal box
.51 Nut
.52 Stirrup
.70 Terminal clip
.71 Outer bearing cap
.72 Grease slinger
.83 Gasket
.84 Cover for terminal box
.89 Screw
.94 Screw
.95 Clip
.96 Supporting bar
.97 Brace complete
.99 Contact washer
6.00
.10
.20
.23
.24
.65
.66
.67
6.00
.10
.20
.23
.24
.65
.66
.67
Bearing assembly, non-drive end

Rolling-contact bearing
Endshield
Shaft sealing ring
Cover of bearing
Nipple
Rubber bush
Lubrication pipe
7.00
.04
.40
.41
.49
Ventilation accesories, complete

Fan
Fan cowl
Angle
Screw
Lagerung BS
Wlzlager
Lagerschild
Wellendichtring
Lagerdeckel
Schmiernippel
Gummibuchse
Schmierrohr
7.00 Belftung, komplett

.04 Lfter
.40 Lfterhaube
.41 Winkel
.49 Schraube
Auf- und Abziehvorrichtungen fr Wlzlager,
Lfter und Abtriebselemente sind nicht lieferbar!
Mounting and extracting devices for rollingcontact bearings, fans and out elements are
not available.

Siemens AG
Les dispositifs demmanchement et

dextraction pour roulements, ventilateurs et
organes de tranasmission ne sont pes livrables.
5.00 Caja de bornes, completa

.03 Junta (en BG 200 obturacin
trenzada)
.10 Placa de bornes, completa
.33 Suplemento fijo
.34 Estribo
.35 Tapn de goma
.44 Parte superior de la caja de bornes
.51 Tuerca
.52 Brida
.70 Estribo
.71 Tapa exterior del cojinete
.72 Anillo de engrase
.83 Junta
.84 Tapa de la caja de bornes
.89 Tornillo
.94 Tornillo
.95 Abrazadera
.96 Listn de soporte
.97 Sostn completo
.99 Plancha de contacto
6.00
.10
.20
.23
.24
.65
.66
.67
Cojinete del LCA

Rodamiento
Escudo portacojinete
Retn
Cubierta del cojinete
Aceitera
Casquillo de goma
Tubo de lubricacin
7.00
.04
.40
.41
.49
Ventilacin, completa
Ventilador
Tapa del ventilador
Angular
Tornillo
No se suministran Ios dispositivos para extraer y calar los rodamientos, el ventilador y

Ios elementos de accionamiento.
- 34 -
ANHANG / APPENDIX / APPENDICE / ANEXO / APPENDICE / BILAGA / DODATEK /

ITALIANO
SVENSKA
ESKY
Parti di ricambio, fornibili dalla fabbrica

(vedi esempio)
Reservdelar, tillgngliga frn

fabriken (se Bestllningsexempel)
Nhradn dly, kter dodv vrobce

(viz pklad objednvky)
, ( )
1.00
.40
.43
.58
.60
.61
.65
.67
.68
.69
Supporto lato comando

Scudo di supporto
Anello torico
Rondella elastica
Cuscinetto a rotolamento
Tappo di chiusura
Copricuscinetto
Copricuscinetto esterno
Disco centrifugo
Molla de compressione
3.00 Rotore, completo

4.00 Statore, completo
.07 Piede del corpo (BG 180 sinistro,
destro)
.18 Targhetta
.35 Disco
.40 Disco
.41 Morsetto di messa a terra
5.00 Scatola morsetti, completa
.03 Guarnizione (nei BG200 guarnizione
a corda)
.10 Morsettiera completa
.33 Supporto antitorsione
.34 Morsetto di serraggio
.35 Tappo in gomma
.44 Parte superiore della scatola
morsetti
.51 Dado
.52 Ponticello diritto
.70 Morsetto di serraggio
.71 Copricuscinetto esterno
.72 Disco centrifugo
.83 Guarnizione
.84 Coperchio della scatola morsetti
.89 Vite
.94 Vite
.95 Morsettiera per circuito
.96 Lista portante
.97 Montante completo
.99 Lamiera di contatto
6.00
.10
.20
.23
.24
.65
.66
.67
Supporto opposto al lato comando

Cuscinetto a rotolamento
Scudo di supporto
Anello torico
Copricuscinetto
Nipplo di lubrificazione
Bussola in gomma
Tubo di lubrificazione
7.00 Ventilazione completa

.04 Ventola
.40 Cuffia della ventola
.41 Angolare
.49 Vite
Non sono fornibili i dispositivi di estrazione /
calettamento per i cuscinetti, ventilatori ed
azionamenti.
1.00 Lager fr axeltappsidan

(A-sidan), komplett
.40 Lagerskld
.43 Ttningsring
.58 Fjderbricka
.60 Rullningslager
.61 Frseglingspropp
.65 Lagerverfall
.67 Yttre lagerlock
.68 Avkastare
.69 Spiralfjder
1.00
.40
.43
.58
.60
.61
.65
.67
.68
.69
3.00 Rotor, komplett
3.00 Rotor pln
3.00
4.00
.07
.18
.35
.40
.41
Stator pln
patka statoru (BG180 - prav, lev)
vkonostn ttek
podloka
podloka
uzemovac spojka
4.00
.07
.18
.35
.40
.41

(BG180 , )

5.00
.03
.10
.33
.34
.35
.44
.51
.52
.70
.71
.72
.83
.84
.89
.94
.95
.96
.97
.99
Svorkovnice pln
tsnn (BG200 tsnic ra)
svorkov deska pln
pevn podloka proti pootoen
upnac tmen
gumov ztka
sk svorkovnice
matice
propojka
U-tmen
loiskov vko vnj
odstikova
tsnn
vko skn svorkovnice
roub
roub
svorka
nosn lita
oprka pln
kontaktn plech
5.00
.03
.10
.33
.34
.35
.44
.51
.52
.70
.71
.72
.83
.84
.89
.94
.95
.96
.97
.99

(BG200 )

6.00
.10
.20
.23
.24
.65
.66
.67
Uloen BS
valiv loisko
loiskov tt
tsnc krouek hdele
loiskov vko
mazac hlavice
gumov pouzdro
mazac trubka
6.00
.10
.20
.23
.24
.65
.66
.67
BS

7.00
.04
.40
.41
.49
Ventilace pln
ventiltor
kryt ventiltoru
helnk
roub
7.00
.04
.40
.41
.49
4.00 Stator, komplett

.07 Kroppens fot (BG 180 - vnstre fot,
hgre fot)
.18 Mrkplt
.35 Bricka
.40 Skiva
.41 Jordledningens klammer
5.00
.03
.10
.33
.34
.35
.44
.51
.52
.70
.71
.72
.83
.84
.89
.94
.95
.96
.97
.99
Uttagslda, komplett
Ttning
Kopplingsplint, komplett
Underlgg, arreterat
Klmbygel
Gummiplugg
Anslutningslda, verdel
Mutter
Bygel
Klmbygel
Yttre lagerlock
Avkastare
Ttning
Lock till uttagslda
Skruv
Skruv
Klmma
Brlist
Full strva
Kontaktplt
6.00
.10
.20
.23
.24
.65
.66
.67
Lager fr flktsidan (B-sidan)

Rullningslager
Lagerskld
Axelttning
Lagerverfall
Smrjkopp
Gummihylsa
Smrjrr
7.00
.04
.40
.41
.49
Flktkylning, komplett
Flkt
Flktkpa
Vinkel
Skruv
P- och avdragare fr rullningslager, flkt

och drivdon kan ej erhllas.
Uloen AS
loiskov tt
tsnc krouek hdele
prun podloka
valiv loisko
uzavrac ztka
loiskov vko
loiskov vko vnj
odstikova
Tlan pruina
Nasazovac a stahovac ppravky pro valiv

loiska, ventiltory a penosov leny se nedodvaj!
1.0
.40
.43
.58
.60
.61
.65
.67
.68
.69
AS

,
!
Bestellbeispiel / Order example

Exemple de commande
Ejemplo de pedido
Esempio di ordinazione
Bestllningsexempel
Pklad objednvky

1LG4183-4AA60
Nr. UC 0008/012783001
1.40 Lagerschild

Siemens AG
- 35 -
Typ / Types / Type / Tipo / Tipo / Type / Type / Tipos / / Type / Tyyppi /
Typy / Type / TEGUND / Tpus / Tip / Typ / Typ / Tp / Tips / Tipas / Tipi
1LA, 1LB, 1LC, 1LD, 1LF, 1LG, 1LL, 1LN, 1LP, 1LS, 1LT, 1LV, 1PG, 1PB, 1PF,
1PK, 1PP, 1PQ, 1PR
DE
EN
FR
ES
IT
SV
NL
PT
EL
DA
FI
CS
HU
SL
SK
Sicherheits- und Inbetriebnahmehinweise fr Niederspannungs-Asynchronmotoren

(gem Niederspannungsrichtlinie 73/23/EWG)
Achshhe:
56 bis 450 mm
Information on safety and commissioning for low voltage asynchronous motors

(in accordance with L. V. directive 73/23/EEC)
Shaft height: 56 to 450 mm
Consignes de scurit et de mise en service pour moteurs asynchrones basse tension

(selon directive basse tension 73/23/CEE)
Hauteur d'axe: 56 450 mm
Advertencias de seguridad y de puesta en marcha para motores asncronos de baja tensin

(segn las Directrices para baja tensin 73/23/CEE)
Altura del eje: 56 ..... 450 mm
Avvertenze per la sicurezza e la messa in servizio di motori asincroni in bassa tensione

(conformemente alla direttiva per impianti impiegati in bassa tensione 73/23/CEE)
Altezza asse: 56 ..... 450 mm
Skerhets- och idrifttagningsanvisningar fr lgspnnings-asynkronmotorer

(enl. lgspnningsdirektivet 73/23/EEC)
Axelhjd: 56 ..... 450 mm
Aanwijzingen voor de veiligheid en het inbedrijfstellen van laagspanningsmotoren

(volgens Laagspanningsrichtlijn 73/23/EEG)
Ashoogte: 56 .....
450 mm
Instrues de segurana e de colocao em funcionamento para motores asncronos de baixa tenso

(em conformidade com a directiva de baixa tenso 73/23/CEE)
Altura do eixo: 56 a 450 mm

56 ...
( 73/23/).
450 mm
Sikkerheds- og ibrugtagningsanvisninger for lavspndings-asynkronmotorer

(i henhold til lavspndingsdirektiv 73/23/EF)
Akselhjde: 56 til 450 mm
Pienjnniteoikosulkumoottoreiden turvallisuus- ja kyttnotto-ohjeet

(pienjnnitedirektiivin 73/23/ETY mukaisesti)
Akselikorkeus: 56 ..... 450 mm
Pokyny o bezpenosti a uvdn do provozu nzkonapovch asynchronnch motor

(podle smrnice pro nzk napt 73/23/EWG)
Osov vky: 56 a 450 mm
Az alacsonyfeszltsg aszinkron-motorokkal kapcsolatos biztonsgi, s indtssal kapcsolatos informcik

(az L. V. 73/23/EEC direktva szerint)
Tengelymagassg: 56 - 450 mm
Informacije o varnosti in uporabi za nizkonapetostne asinhrone motorje

(v skladu s smernico L. V. 73/23/EEC)
Viina osi:
56 do 450 mm
Informcie o bezpenosti a uveden do prevdzky pre nzkonapov asynchrnne motory
(poda smernice L. V. 73/23/EEC)
Dka hriadea: 56 a 450 mm
PL
Informacje dotyczce bezpieczestwa i konfekcjonowania niskonapiciowych silnikw asynchronicznych
ET
Madalpinge-asnkroonmootorite ohutusteave ja kikuandmine
LV
Informcija par drobu un zemsprieguma asinhrono motoru nodoanu ekspluatcij
LT
MT
(zgodnie z dyrektyw L. V. 73/23/EEC)
Wysoko wau: 56 do 450mm
(vastavalt madalpingeelektriseadmete direktiivile 73/23/EEC)

(atbilstoi direktvai par zemspriegumu 73/23/EEC)
Veovlli krgus: 56450 mm

Vrpstas augstums:
56450 mm
Informacija apie emos tampos asinchronini varikli saug ir eksploatavim

(pagal L. V. direktyv 73/23/EEC)
Veleno auktis: nuo 56 iki 450 mm
Tagrif dwar is-sigurt u taddim ta' muturi asinkroni b'vulta baxx

(b'mod konformi mad-direttiva L.V 73/23/KEE)
Ausgabe / Edition 06.2004
L-goli tax-xaft: 56 sa 450 mm
Bestell - Nr. / Order No.: 5 610 70000 38 006
DEUTSCH / ENGLISH / FRANAIS / ESPAOL / ITALIANO / SVENSKA / NEDERLANDS /

Slovenina / Slovensky / POLSKI / EESTI / Latviski / Lietuvikai / Malti
PORTUGUS / / DANSK / SUOMI / esky / Magyar /
DE
DEUTSCH
Bei Wellenende nach oben mu das Eindringen von Wasser entlang
Elektromotoren haben gefhrliche, spannungsfhrende und der Welle verhindert werden.
rotierende Teile sowie mglicherweise heie Oberflchen. Alle Belftung nicht behindern! Abluft - auch benachbarter Aggregate Arbeiten zum Transport, Anschlu, zur Inbetriebnahme und darf nicht unmittelbar wieder angesaugt werden.
regelmige Instandhaltung sind von qualifiziertem, verantwortlichem Fachpersonal auszufhren (VDE 0105; IEC 364 beachten). 5 Elektrischer Anschlu
Unsachgemes Verhalten kann schwere Personen- und Alle Arbeiten drfen nur von qualifiziertem Fachpersonal am
Motor
im
freigeschalteten
und
gegen
Sachschden verursachen. Die jeweils geltenden nationalen, stillstehenden
Wiedereinschalten
gesicherten
Zustand
vorgenommen
werden.
rtlichen
und
anlagespezifischen
Bestimmungen
und
Dies gilt auch fr Hilfsstromkreise (z.B. Stillstandsheizung).
Erfordernisse sind zu bercksichtigen.
Spannungsfreiheit prfen !
berschreiten der Toleranzen in EN 60034 - 1 / IEC 34-1 2 Bestimmungsgeme Verwendung
Spannung 5%, Frequenz 2%, Kurvenform, Symmetrie - erhht die
Diese Motoren sind fr gewerbliche Anlagen bestimmt. Sie
Erwrmung und beeinflut die elektromagnetische Vertrglichkeit.
entsprechen den harmonisierten Normen der Reihe EN 60034 (VDE
Leistungsschildangaben
sowie
das
Anschluschema
im
0530). Der Einsatz im Ex-Bereich ist verboten, sofern nicht
Anschlukasten beachten.
ausdrcklich hierfr vorgesehen (Zusatzhinweise beachten). Falls
Der Anschlu mu so erfolgen,da eine dauerhaft sichere,
im Sonderfall - bei Einsatz in nicht gewerblichen Anlagen - erhhte
elektrische Verbindung aufrecht erhalten wird (keine abstehenden
Anforderungen gestellt werden (z. B. Berhrungsschutz gegen
Drahtenden); zugeordnete Kabelendbestckung verwenden. Sichere
Kinderfinger), sind diese Bedingungen bei der Aufstellung
Schutzleiterverbindung herstellen.
anlagenseitig zu gewhrleisten.
Anziehdrehmomente fr Klemmenplatten-Anschlsse siehe Fig. 1.
Die Motoren sind fr Umgebungstemperaturen von -20C bis +40C
sowie Aufstellungshhen 1000 m ber NN bemessen. Luftabstnde
zwischen blanken, spannungsfhrenden Teilen
Abweichende Angaben auf dem Leistungsschild unbedingt untereinander und gegen Erde 5,5 mm (UN 690 V).
beachten.Die
Bedingungen
am
Einsatzort
mssen
allen Im Anschlukasten drfen sich keine Fremdkrper, Schmutz sowie
Leistungsschildangaben entsprechen.
Feuchtigkeit befinden. Einfhrungen in dem Anschlukasten (siehe
Niederspannungsmotoren sind Komponenten zum Einbau in DIN 42925), weitere offene Einfhrungen sind mit O-Ring oder
Maschinen im Sinne der Maschinenrichtlinie 89/392/EWG. Die geeigneter Flachdichtung, der Anschlukasten selbst mit der
Inbetriebnahme ist solange untersagt, bis die Konformitt des Originaldichtung staub- und wasserdicht verschlieen.
Endproduktes mit dieser Richtlinie festgestellt ist (EN 60204-1 Anziehdrehmomente fr Kabelverschraubungen siehe Fig. 2.1, fr
sonstige Schrauben siehe Fig. 3.
beachten).
1 Allgemein
Fr den Probebetrieb ohne Abtriebselemente Pafeder sichern.

Bei Motoren mit Bremse vor der Inbetriebnahme die einwandfreie
Nach der Auslieferung festgestellte Beschdigungen dem Funktion der Bremse prfen.
Transportunternehmen sofort mitteilen; die Inbetriebnahme ist ggf.
auszuschlieen. Beim Transport sind alle vorhandenen Hebesen am 6 Betrieb
Motor zu benutzen, eingeschraubte fest anziehen! Sie sind nur fr Schwingstrken v 3,5 mm/s (P 15 kW) bzw. v 4,5 mm/s
eff
N
eff
das Gewicht des Motors ausgelegt, keine zustzlichen Lasten
(PN > 15 kW) sind im gekuppelten Betrieb unbedenklich.
anbringen. Wenn notwendig, geeignete, ausreichend bemessene
Bei Vernderungen gegenber dem Normalbetrieb - z.B. erhhte
Transportmittel (z.B. Seilfhrungen) verwenden.
Vorhandene Transportsicherungen vor Inbetriebnahme entfernen. Temperaturen, Gerusche, Schwingungen - ist im Zweifelsfall der
Motor abzuschalten. Ursache ermitteln, eventuell Rcksprache mit
Fr weitere Transporte erneut verwenden.
Werden Motoren eingelagert, auf eine trockene, staubfreie und dem Hersteller. Schutzeinrichtungen auch im Probebetrieb nicht
schwingungsarme (veff 0,2 mm/s) Umgebung
achten auer Funktion setzen.
Bei starkem Schmutzanfall
Luftwege regelmig reinigen.
(Lagerstillstandsschden).
Vorhandene verschlossene Kondenswasserlcher von Zeit zu Zeit
Bei lngerer Einlagerungszeit verringert sich die Fettgebrauchsdauer
ffnen!
der Lager. Bei Lagerung ber 12 Monate ist eine berprfung des
Unabhngig von den Betriebsstunden eines im Einsatz befindlichen
Fettzustandes durchzufhren. Falls die berprfung eine
Motors sollte das Wlzlager, wegen der Reduzierung der
Verschmutzung des Fettes erkennen lsst, (Eindringen von
Kondenswasser fhrt zu Konsistenznderungen des Fettes) muss das Schmierfhigkeit, etwa alle 3 Jahre erneuert werden.
Bei Motoren ohne
Nachschmiereinrichtung
Lager- bzw.
Fett ausgetauscht werden.
Fettwechsel nach Herstellerangaben, sptestens jedoch nach 3
Isolationswiderstand
Der Mindestisolationswiderstand von neuen, gereinigten oder Jahren.
Bei Motoren mit Nachschmiereinrichtung sind die Angaben auf
instandgesetzten Wicklungen gegen Masse betrgt 10 M.
dem Schmierschild oder Leistungsschild
zu beachten!
Die
Vor Inbetriebnahme Isolationswiderstand messen.
Nachschmierung sollte bei laufendem Motor erfolgen!
Bei Werten 0,5 M/kV Bemessungsspannung Wicklung trocknen.
Bei Motoren mit Zylinderrollenlager fr erhhte Radialbelastung
werden
durch
den
Betrieb
mit
kleinerer
als
der
4 Aufstellung
Mindestradialbelastung
Schdigungen
verursacht.
Die
Eingeschraubte Hebesen sind nach dem Aufstellen fest anzuziehen Radialbelastung sollte im Betrieb mindestens 30 % der zulssigen
oder zu entfernen!
Radialbelastung betragen (siehe Katalog). Bei
Motoren mit
Auf gleichmige Auflage, gute Fu- bzw. Flanschbefestigung und Fremdbelftung mu der Fremdlfter bei Betrieb eingeschaltet sein.
genaue Ausrichtung bei direkter Kupplung achten. Aufbaubedingte
Resonanzen mit der Drehfrequenz und der doppelten Netzfrequenz
7 Weitere Informationen
vermeiden. Lufer von Hand drehen, auf ungewhnliche
Informationen ber
eventuelle
Zusatzeinrichtungen sind zu
Schleifgerusche achten. Drehrichtung im ungekuppelten Zustand
beachten, wie z.B. diverse Hinweise der Hersteller fr
kontrollieren (Abschnitt 5 beachten).
Kabelverschraubungen einschlielich Dichtungselemente! Weitere
Abtriebselemente (Riemenscheibe, Kupplung ...) nur mit geeigneten
Einzelheiten enthalten unsere ausfhrlichen
Betriebs- und
Vorrichtungen auf- bzw. abziehen (Erwrmen!) und mit einem
Instandhaltungsanleitungen. Sie werden Ihnen auf Wunsch, unter
Berhrungsschutz abdecken. Unzulssige Riemenspannungen
Angabe des Typs und der Maschinen-Nummer, zugeschickt oder
vermeiden (Katalog, Techn. Liste).
knnen unter www.siemens.com/motors nachgeschlagen werden.
Wuchtzustand
siehe
Wellenspiegel
oder
Leistungsschild
Diese
Sicherheits- und
Inbetriebnahmehinweise
sind
(H = Halb-, F = Vollkeilwuchtung, N = Auswuchtung ohne Passfeder)
aufzubewahren!
DIN IEC ISO 8821. Bei Montage des Abtriebselementes auf
Wuchtzustand achten!
Bei Einsatz oder Lagerung im Freien wird der berbau oder eine
zustzliche Abdeckung empfohlen, so da eine Langzeiteinwirkung
bei direkter intensiver Sonneneinstrahlung, Regen, Schnee, Eis oder
auch Staub vermieden wird.
3 Transport, Einlagerung
ENGLISH
EN
1 General information
5 Electrical connection
Electric motors have dangerous voltage-carrying and rotating

components as well as surfaces that may become hot. All work
involved in the transport, connection, commissioning and regular
maintenance must be carried out by qualified, responsible
specialists (note VDE 0105; IEC 364). Improper behaviour may result
in serious injury and damage to property. The applicable national,
local and works regulations and requirements must be complied
with.
Work is only permitted to be carried out by qualified specialists on

the stationary motor, while disconnected and prevented from
being switched on again. This also applies for the auxiliary power
circuits (e.g. Anti-condensation heaters).
Check that the equipment is potential-free!
If the tolerance limits are exceeded that are specified in EN
60034, part 1 / IEC 34-1 (voltage 5%, frequency 2%, shape of
curve, symmetry) the heating effect is increased and the
electromagnetic compatibility is affected. Please note the
specifications on the rating plate and the connection diagram in the
terminal box.
Connections must be made in such a way as to ensure that a
permanently safe electrical connection is maintained (no protruding
wire ends); use the corresponding cable end pieces. Create a safe
earth continuity connection.
See Fig. 1 for the tightening torques for terminal board connections.
2 Intended use
These motors are intended for commercial installations. They comply
with the harmonized standards of the EN60034 (VDE 0530) series.
Utilization in areas subject to explosion hazard is not permitted,
unless expressly intended for this purpose (see additional notes). In
certain special cases, for example, on use in non-commercial
installations, if requirements are more strict (e.g. protection against
contact with childrens fingers), it is the responsibility of the customer
to ensure compliance on installing the equipment.
The motors are rated for ambient temperatures of -20C to +40C and
site altitudes 1000 m above sea level. Any contradictory
information on the rating plate must be observed. The conditions on
site must correspond to all rating plate specifications.
Clearences in air between bare live parts themselves and between

bare live parts and earth must be 5,5 mm (Urated 690 V) .
It must be ensured that the terminal box does not contain foreign
bodies, dirt or humidity. Seal any unused cable entry openings
against dust and water.
Inlets in the terminal box (see DIN 42925), other open inlets must be
Low voltage motors are components for installation in machinery sealed with an O-ring or a suitable flat gasket, and the terminal box
in terms of the Machine directive 89/392/EEC. Commissioning itself must be sealed with the original seal so that it is dustproof and
must not take place until it has been proved that the end product watertight.
See Fig. 2.1 for the tightening torques for cable glands and Fig. 3 for
conforms with this guideline (please note EN 60204-1).
other screws.
Secure the featherkey on test operation without drive components.
3 Transport and storage
For
motors with brakes, check that the brakes are operating perfectly
In the case of damage determined after delivery this must be
immediately reported to the transport company; if necessary the before commissioning.
plant is not to be put into commission. During transportation all the
available lifting eyes in the motor are to be used and be done up tight 6 Operation
when fitted! They are only designed and built for the weight of the Vibration levels of vr m s 3.5 mm/s (PN 15 kW) or vr m s 4.5 mm/s
motor. Do not load additionally. If necessary use suitable adequately (PN > 15 kW) are quite acceptable in the coupled state.
dimensioned transporting means (for example, rope guides).
If deviations from normal operation occur - e.g. increased
Remove existing shipping braces before commissioning; and reuse temperatures, noises, vibration - the motor should be switched off
for subsequent transport. If motors are stored, a dry, dust-free and in the event of doubt. Determine the causes and contact the
low vibration (vr m s 0.2 mm/s) environment is important (to avoid manufacturer if necessary. Do not disconnect protective equipment,
bearing standstill damage). On long-term storage, the regrease even under test operation.
interval of the bearings is reduced.
Under dirty operating conditions, clean the air channels regularly.
The state of the grease is to be checked when storing for more than Open any closed condensate water holes from time to time!
12 months. Should it be determined that the grease has become Irrespective of the number of operating hours, a motor which is in
contaminated (penetration of condensation water leads to changes in use should have its bearing replaced every 3 years because of the
the consistency of the grease) then the grease must be replaced.
reduction in effectiveness of the grease.
For motors without regreasing points, bearings and/or the grease
Insulation resistance
are to be replaced in accordance with the manufacturers instructions
The minimum insulation resistance of new, cleaned or repaired at least every three years.
windings should be 10 M to earth
For motors with regreasing points, the instructions on the
Check the insulation resistance before commissioning. For values lubrication data plate must be observed! Regreasing should be
0.5 M/kV design voltage dry the windings.
performed on running motors!
Damage will be caused when operating at lower than minimum radial
stress in the case of motors with cylindrical roller bearings for higher
4 Installation
After installation, the screwed-in lifting eyes should either be screwed radial load. The radial stress is to be minimum 30 % of the permissible
radial stress in operation (see catalogue).
in tightly or removed!
Ensure an even underlying surface, good foot or flange fixing and In the case of motors with separate ventilation, the separatelyprecise alignment for direct coupling. It is important to ensure that driven fan must be switched on throughout motor operation.
the mounting conditions do not cause resonance with the rotational
frequency and the doubled supply frequency. Turn the rotor by hand 7 Further information
and listen for any unusual grinding noises. Check the direction of Information about any additional equipment, such as the different
rotation in the decoupled state (note section 5).
manufacturers instructions for cable connections including sealing
Only mount or remove drive components (belt pulley, coupling, etc.) elements, shall be observed. More information is available in our
using suitable tools (heat up), and cover to shield against contact. detailed operating and maintenance instructions. On request you will
Avoid unpermissible belt tensions (see catalogue and technical data). be sent further details if you state the type and machine number or,
Balance see shaft end face or the ratings plate (H = Half key you can find these under www.siemens.com/motors.
balancing, F = Full-key balancing, N = Balancing without featherkey) These notes on safety and commissioning must be retained for future
DIN IEC ISO 8821. Check the balance when fitting the drive element! reference!
For use or storage outside, it is recommended that the motor is
installed under a sheltering object or fitted with an additional cover to
avoid the long-term effects of direct sunlight, rain, snow, ice or dust.
Where shaft ends face upwards water must not be allowed to enter
along the shaft.
Do not obstruct ventilation! Discharged air, also from neighbouring
equipment, must not be sucked in again immediately.
FR
FRANAIS
5 Raccordement lectrique
1 Gnralits
Les moteurs lectriques comportent des pices dangereuses, sous

tension ou rotatives, et ventuellement des surfaces portes haute
temprature. Tous les travaux de manutention, raccordement, mise
en service et entretien rgulier sont excuter par des personnes
qualifies responsables (respecter VDE 0105; CEI 364). Un
comportement inappropri peut occasionner des blessures graves et
des dommages matriels importants. Il convient de respecter les
normes et dispositions nationales, locales et spcifiques de
ltablissement.
2 Utilisation conforme
Ces moteurs sont destins lemploi industriel. Ils sont conformes

aux normes harmonises de la srie EN60 034 (VDE 0530).
Lutilisation en atmosphre explosible est interdite, sauf
autorisation expresse (consignes complmentaires). Si des emplois
particuliers dans des tablissements non industriels imposent des
contraintes de scurit plus svres (ex. protection contre les
contacts de doigts denfant), les mesures de protection sont prendre
par le client au moment de linstallation. Les moteurs sont conus
pour des tempratures ambiantes de -20C +40C et une altitude
dinstallation 1000 m. Respecter imprativement les indications
divergentes sur la plaque signaltique. Les conditions sur le site
doivent tre conformes en tout point avec les indications de la
plaque signaltique.
Les moteurs basse tension sont des composants intgrer dans
des machines au sens de la directive machines 89/392/CEE. La
mise en service est interdite tant que la conformit du produit
fini avec cette directive nest pas constate (EN 60204-1).
Tous les travaux ne doivent tre raliss que par des personnes
qualifies sur le moteur larrt, hors tension et condamn. Ceci
sapplique aussi aux circuits auxiliaires (ex. chauffage larrt).
Vrifier labsence de tension !
Le dpassement des tolrances spcifies dans EN 60034 , partie 1 /
CEI 34-1 tension 5%, frquence 2%, forme donde, symtrie
accrot
lchauffement
et
influe
sur
la
compatibilit
lectromagntique. Respecter les indications de la plaque
signaltique ainsi que le schma de branchement dans la bote
bornes.
Le branchement est raliser de faon tablir une liaison lectrique
scurit durable (pas dextrmits de fils en lair) ; quiper en
consquence les extrmits des conducteurs. Etablir des connexions
sres du conducteur de protection.
Couples de serrages pour des connexions des plaques bornes cf. fig
1.
Distances dans l'air des parties nues sous tension entre elles et par
rapport la terre 5,5 mm (UN 690 V).
La bote bornes doit tre exempte de corps trangers, de salets et
dhumidit. Les entres dans la bote de connexion (cf. DIN 42925) et
autres entres ouvertes sont rendre tanches laide de joints
toriques ou autres joints dtanchit, la bote des connexion doit tre
rendue tanche leau et la poussire laide du dispositif
dtanchit dorigine.
Couples de serrage pour raccords vis cf. fig. 2.1, pour dautres vis cf.
fig. 3.
Pour la marche dessai sans organes de transmission, assujettir la
clavette larbre. Sur les moteurs avec frein vrifier le
fonctionnement correct du frein avant la mise en service.
6 Fonctionnement
3 Transport, entreposage
Aprs livraison, communiquer immdiatement lentreprise ayant

assum le transport tous les dommages constats; exclure
ventuellement toute mise en service. Pour le transport, utiliser tous
les illets de levage se trouvant sur le moteur, serrer correctement
les illets visss! Ces dispositifs de levage sont seulement
dimensionns pour supporter le poids du moteur, ne pas ajouter de
charges supplmentaires. Si ncessaire, utilis un dispositif de
transport appropri et suffisamment dimensionn (par exemple
guidage par cbles).
Avant la mise en service, enlever les protections pour le transport.
Les conserver pour une rutilisation ultrieure ventuelle. Pour
lentreposage des moteurs, veiller un environnement sec, non
poussireux et exempt de vibrations (veff 0,2 mm/s) (dgradation
des roulements larrt). Un entreposage de longue dure rduit la
dure dutilisation de la graisse des roulements. En cas de stockage
sur une dure de plus de 12 mois, un contrle de ltat de la graisse
doit tre effectu. Si ce contrle montre un encrassement de la
graisse (lintroduction deau de condensation entrane une
modification de la consistance de la graisse), il faut changer la
graisse.
Rsistance disolement
La rsistance disolement minimale denroulements neufs, nettoys
ou remis en tat contre la masse est de 10 M.
Mesurer la rsistance disolement avant la mise en service. Pour les
valeurs de tension dimensionnes
0,5 M/kV, scher
lenroulement.
Les
vibrations
veff 3,5 mm/s (PN 15 kW) ou veff 4,5 mm/s
(PN > 15 kW) sont inoffensives ltat accoupl. Si lon constate des
conditions divergentes du rgime normal ex. surchauffement,
bruit, vibrations arrter le moteur en cas de doute. Dterminer la
cause ; consulter ventuellement le constructeur. Ne pas rendre
inoprant les dispositifs de protection, mme pas en marche dessai.
En atmosphre sale et poussireuse, nettoyer rgulirement les
circuits dair. Ouvrir de temps autre les purgeurs de condensat.
Sur les moteurs sans graisseur, remplacer les roulements ou la
graisse en se conformant aux indications du constructeur, et au plus
tard aprs trois ans.
Indpendamment du nombre dheures de service dun moteur en

service, lappui rouleaux doit tre chang peu prs tous les trois
ans du fait de la rduction du pouvoir lubrifiant.
Pour les moteurs sans dispositif de regraissage, changement des
paliers et de la graisse selon les indications du fabricant, toutefois au
plus tard 3 ans plus tard.
Pour les moteurs avec dispositif de regraissage, respecter les
indications donnes sur la plaque de graissage ou sur la plaque
signaltique ! Le regraissage doit avoir lieu quand le moteur est en
marche !
Avec les moteurs quips de roulements rouleaux cylindriques pour
charge radiale importante, une utilisation avec une charge infrieure
la charge radiale minimale entrane des endommagements. La
charge radiale doit tre en exploitation au moins gale 30% de la
charge radiale admissible (voir catalogue).
Dans le cas de moteurs refroidissement spar, le
motoventilateur doit tre en marche lors du fonctionnement du
4 Installation
Si les illets de levage sont visss, les serrer fond aprs linstallation moteur.
ou les retirer !
Veiller un appui plan, une bonne fixation des pattes ou de la bride 7 Informations complmentaires
et un alignement prcis des lignes darbres en cas daccouplement Respecter les informations donnes sur les ventuels dispositifs
direct. Eviter les rsonances la simple ou double frquence de supplmentaires, comme par ex. les diffrentes notes des fabricants
rotation dues aux conditions de montage. Tourner le rotor la main pour les passe-cble vis, y compris les lments dtanchit !
pour dceler dventuels bruits de frottement anormaux. Contrler le Vous trouverez dautres dtails dans nos instructions de service et de
maintenance. Ils vous seront envoys sur demande moyennant
sens de rotation ltat dsaccoupl (voir chap. 5)
Ne monter et dmonter les organes de transmission (poulie, indication du type et du numro de lappareil, mais vous pouvez
les
obtenir
sur
linternet
en
consultant
accouplement, ...) quavec les dispositifs appropris (en chauffant !) galement
et les placer sous carter de protection. Tendre les courroies aux www.siemens.com/motors Conserver soigneusement les prsentes
consignes de scurit et de mise en service !
valeurs prescrites (catalogue, liste technique).
Etat dquilibrage cf. sur le bout de larbre ou sur la plaque

signaltique (H = quilibrage demi-clavette, F = quilibrage clavette
pleine, N = quilibrage sans clavette).
DIN IEC ISO 8821; Lors du montage des lments de lentranement il
faut tenir compte de ltat dquilibrage.
Lors de lutilisation ou du stockage lair libre, il est recommand de
prvoir une construction en saillie ou un recouvrement
supplmentaire afin dviter les effets long terme des rayons directs
du soleil, de la pluie, de la neige, de la glace et aussi de la poussire.
Quand le bout de larbre est en haut, il faut empcher que de leau
pntre le long de larbre.
Ne pas entraver la ventilation : lair vacu aussi de machines
voisines ne doit pas tre directement raspir.
4
ESPAOL
ES
1 Generalidades
No impedir la ventilacin! Evitar la aspiracin directa del aire

Los motores elctricos tienen piezas, peligrosas, bajo tensin y en expulsado, tambin la de mquinas vecinas.
movimiento as como posiblemente superficies a alta temperatura.
Todos los trabajos de transporte, conexin, puesta en marcha y 5 Conexin elctrica
mantenimiento peridico han de ser realizados por personal Todos los trabajos deben ser realizados por personal cualificado en
especializado y cualificado responsable (observar VDE 0105; IEC motores parados, que han sido aislados de la red y asegurados
364). Un comportamiento inadecuado puede producir graves contra la reconexin (condenado). Esto rige tambin para los
lesiones y daos materiales. Es necesario respetar las normas y circuitos auxiliares (p. ej. la calefaccin contra condensaciones).
disposiciones vigentes nacionales, locales y especficas de la Comprobar la ausencia de tensin!
instalacin.
Si se sobrepasan las tolerancias especificadas en EN 60034, parte
1/IEC 34-1 (tensin 5%, frecuencia 2%, forma de onda, simetra)
aumenta el calentamiento y disminuye la compatibilidad
2 Utilizacin conforme
Estos motores estn destinadas a instalaciones industriales. Cumplen electromagntica. Observar los datos en la placa de caractersticas as
con las normas armonizadas de la serie EN60034 (VDE 0530). Est como el esquema en la caja de conexiones.
prohibida su aplicacin en recintos expuestos al peligro de Las conexiones se realizarn de forma que quede asegurada una
explosiones (Ex) a no ser que se hayan destinado expresamente a conexin elctrica fiable y duradera (nada de extremos de hilos al
este efecto (observar las advertencias adicionales). Si en casos aire); usar terminales de cable adecuados. Unir a un conductor de
especiales, cuando se utilizan en recintos no industriales, se imponen proteccin.
exigencias de seguridad ms severas (p. ej., proteccin contra Vase los momentos de par de apriete para la placa de bornes vase
contactos involuntarios con dedos de nio), la responsabilidad corre a la fig. 1.
Distancias al aire de las partes sometidas a tensin entre elles y con
cargo del instalador.
Los motores se han diseado para temperaturas ambiente de -20C a relacin a tierra 5,5 mm (UN 690 V).
+40C y una altura de instalacin de hasta 1000 m.s.n.m. Es En la caja de conexin no deben haber cuerpos extraos, suciedad ni
imprescindible observar los datos en la placa de caractersticas. Las humedad.
condiciones en el lugar de emplazamiento deben coincidir con todas las Entradas en la caja de conexiones (vase DIN 42925); obturar contra
el polvo y el agua las otras entradas abiertas con un anillo trico o
indicaciones en dicha placa.
con juntas planas apropiadas y la caja de conexiones propiamente
Los motores de baja tensin son componentes para incorporar en dicha con la junta original.
mquinas
segn la Directiva para mquinas 89/392/CEE. Est Vase los momentos de par de apriete para atornillados para cables
prohibida la puesta en marcha hasta tanto no se haya comprobado en la fig. 2.1, y el resto de los tornillos en la fig. 3.
que el producto final cumple con dicha Directiva (observar EN Para marcha sin elementos de transmisin, asegurar la chaveta contra
su desprendimiento accidental. Comprobar el funcionamiento de los
60204-1).
frenos antes de la puesta en marcha en los motores provistos de los
mismos.
3 Transporte, almacenamiento
En caso de que despus de la entrega sean constatados deterioros,
por favor, comunquelo inmediatamente a la empresa de transporte 6 Servicio
y, en el caso dado, evite la puesta en marcha. En el transporte hay Son despreciables las vibraciones vef 3,5 mm/s (PN 15 kW)
que usar todas las armellas de elevacin en el motor y fijar bien las vef 4,5 mm/s (PN > 15 kW) en servicio con acoplamiento.
enroscadas. Estas armellas son dimensionadas solamente para el Si se observan divergencias durante el servicio respecto al servicio
peso del motor, no se deben colocar cargas adicionales. En caso normal, p. ej. temperatura elevada, ruidos, vibraciones, deber
necesario, hay que utilizar medios de transporte apropiados y desconectarse el motor en caso de duda. Indagar la causa y en caso
suficientemente dimensionados (por ejemplo: guas de cable).
dado consultar con el fabricante. No dejar fuera de servicio, ni
Los seguros de transporte habrn de retirarse antes de la puesta en durante la marcha de prueba, los dispositivos de proteccin.
marcha. Volver a utilizarlos para otros transportes. Si han de Limpiar los conductos de aire peridicamente si hay mucha suciedad.
almacenarse los motores y para evitar daos de parada de los Abrir de tanto en tanto los orificios de purga del agua de
rodamientos, cuidar que el ambiente sea seco, libre de polvo y condensado.
con
pocas
vibraciones (vef 0,2 mm/s). El almacenamiento Independientemente de las horas de servicio de un motor que
trabaja, los rodamientos tienen que renovarse cada 3 aos
prolongado acorta la vida til de la grasa de los rodamientos.
En caso de almacenajes de ms de 12 meses, hay que llevar a cabo aproximadamente, debido a que se reduce la capacidad de
una verificacin del estado de la grasa. En caso de que la verificacin lubricacin.
ponga de manifiesto una contaminacin de la grasa (la penetracin Los motores sin dispositivo de reengrase debern reengrasarse o se
de agua de condensacin provoca una alteracin de la grasa en reemplazarn los rodamientos de acuerdo con las indicaciones del
fabricante, a ms tardar despus de 3 aos.
cuanto a consistencia) hay que cambiar la grasa.
Con motores sin dispositivos de relubricacin se cambian los
Resistencia de aislamiento
La resistencia de asilamiento mnima de arrollamientos contra la rodamientos o bien la grasa segn las especificaciones del fabricante,
pero lo ms tardar, despus de 3 aos.
masa nuevos, limpios o reparados es de 10 M.
Antes de la puesta en marcha medir la resistencia del aislamiento. Si Con motores con dispositivo de relubricacin se tienen que
observar las especificaciones que se hallan en la placa de lubricacin
el valor es 0,5 M/kV de la tensin asignada, secar los devanados.
o de caractersticas! Se tiene que relubricar con el motor en marcha!
En motores con rodamientos de rodillos cilndricos para carga radial
4 Instalacin
Las argollas de elevacin enroscadas debern apretarse o retirarse elevada, se provocan deterioros por un funcionamiento con cargas
radiales inferiores a la carga radial mnima. En funcionamiento, la
despus del montaje!
Cuidar que la conformacin de los cimientos, que la fijacin de las carga radial debera ser como mnimo un 30% de la carga radial
patas y de las bridas sea ptima y que la alineacin sea exacta en el admisible (ver catlogo).
caso de acoplamiento directo. Evitar las resonancias a la frecuencia En le caso de motores con refrigeracin separada, el
simple o doble de rotacin causadas por las condiciones de montaje. motoventilador debe estar en marcha durante el funcionamiento del
Girar a mano el rotor y observar si se oyen ruidos de rozamiento motor.
anmalos. Controlar la direccin de giro en estado desacoplado (ver
el apartado 5).
7 Otras informaciones
Calar o extraer los elementos de transmisin (polea, acoplamiento ...) Hay que tener en cuenta las informaciones acerca de eventuales
slo con el dispositivo adecuado (en caliente!) y cubrirlos con una dispositivos adicionales tales como, p.ej., diversas advertencias de los
proteccin contra contactos involuntarios. Tensar las correas a los fabricantes para conectores para cables incluso elementos
valores prescritos (v. Catlogo, lista de datos tcnicos).
obturadores!Para ms detalles ver nuestras extensas Instrucciones de
Estado de equilibrado, vase el eje de salida o la placa de servicio y mantenimiento. A su peticin se los mandaremos por
caractersticas (H = medio-, F = completo con chaveta, N = correo, con indicacin del tipo y del nmero de mquina, o Vd. puede
equilibrado sin chaveta) DIN IEC ISO 8821. Observe el estrado de verlos en Internet bajo www.siemens.com/motors
equilibrado durante el montaje de los elementos de accionado!
Guardar estas advertencias de seguridad y de puesta en marcha!
Al trabajar o almacenar el equipo al aire libre se recomienda una
sobreestructura o una cubierta adicional de modo que se evite un
efecto a largo plazo con una radiacin solar intensiva directa, lluvia,
nieve, hielo o tambin polvo. Si el extremo del rbol indica hacia
arriba se tiene que evitar que penetre agua a lo largo del rbol.
En caso de montaje con el eje hacia arriba se debe prever una
cubierta que impida la penetracin de agua a lo largo del eje.
ITALIANO
Quando lestremit dellalbero rivolta verso lalto deve essere
Alcune parti dei motori elettrici sono pericolose in quanto in tensione impedita la penetrazione di acqua lungo lalbero.
o in movimento. Altrettanto vale per le superfici, che possono Non ostacolare la ventilazione! Laria scaricata, compresa quella
raggiungere temperature elevate. Tutte le operazioni di trasporto, proveniente da altri gruppi, non deve essere riaspirata subito.
IT
1 Generalit
collegamento, messa in servizio e manutenzione devono essere

eseguite da personale addestrato (cfr. VDE 0105; IEC 364). La non
osservanza di tali norme pu provocare gravi lesioni alle persone
ed ingenti danni materiali. Si raccomanda di rispettare i
regolamenti nazionali e locali e di attenersi alle istruzioni relative
allimpianto.
2 Uso appropriato
I motori sopraelencati sono destinati ad impianti industriali. Essi sono

conformi alle norme armonizzate della serie EN 60034 (VDE 0530).
Limpiego in ambienti potenzialmente esplosivi non consentito
salvo dichiarazione contraria nelle istruzioni (cfr. avvertenze
supplementari). Qualora il motore debba essere incorporato in
impianti non industriali, assolutamente necessario provvedere a
misure di sicurezza supplementari (es. protezioni da contatti per
bambini ). Tali misure devono essere realizzate al momento
dellinstallazione.
I motori sono tarati per temperature ambiente tra - 20C e + 40C e
per altitudini non superiori a 1000 m s.l.m. Si raccomanda di
osservare comunque i dati di targa ai quali devono corrispondere
tutte le condizioni ambientali del luogo di installazione.
I motori a bassa tensione sono componenti da integrarsi in
macchine ai sensi della direttiva CEE 89/392 relativa alle macchine.
La messa in servizio non consentita fin tanto che non stata
accertata la conformit del prodotto finale a detta direttiva
(osservare EN 60204-1).
3 Trasporto, immagazzinaggio
Danni rilevati dopo il disimballaggio vanno comunicati

immediatamente allo spedizioniere. Se necessario in questo caso non
va effettuata una messa in funzione. Per il trasporto bisogna utilizzare
tutti gli occhielli di sollevamento previsti sul motore, serrare bene gli
occhielli avvitati! Essi sono concepiti solo per il peso del motore, non
attaccare pesi supplementari. Se necessario utilizzare mezzi di
trasporto con sufficiente capacit (ad esempio guide a funi).
Prima di procedere alla messa in servizio asportare tutte le parti
utilizzate per assicurare limpianto durante il trasporto. Tali parti
devono essere conservate per eventuali trasporti successivi. Qualora
i motori vengano immagazinati, scegliere un luogo asciutto, privo
di polveri e vibrazioni. (veff 0,2 mm/s) onde evitare danni ai
cuscinetti. Un periodo di immagazzinaggio prolungato comporta la
diminuzione della durata del grasso.
Prima della messa in funzione misurare la resistenza disolamento. In
caso di stoccaggio di oltre 12 mesi bisogna controllare lo stato del
grasso. Se nel controllo si rileva dello sporco nel grasso (la
penetrazione di condensa cambia la consistenza del grasso) bisogna
sostituire il grasso.
Resistenza di isolamento
La resistenza di isolamento minima di avvolgimenti nuovi, puliti o
sottoposti a manutenzione pari a 10 M.
Prima della messa in funzione misurare la resistenza di isolamento.
Con valori inferiori a 0,5 M/kV di tensione nominale asciugare gli
avvolgimenti.
4 Installazione
Dopo il posizionamento i golfari devono essere avvitati con forza

oppure rimossi!
Il motore deve essere installato su superficie piana. Accertarsi che i
piedini o la flangia siano ben serrati e che, nel caso di giunto diretto,
il motore sia perfettamente allineato.Evitare che si creino risonanze
pari alla frequenza dei giri del motore o doppie della frequenza di
rete. Far ruotare manualmente il rotore per verificare lassenza di
rumori di strisciamento. Verificare il senso di rotazione con giunto
disinnestato (cfr. par. 5).
Calettare (estrarre) gli elementi condotti, es. puleggia per
trasmissione a cinghia, giunto ecc., solo mediante dispositivi appositi
(calettamento a caldo). Evitare tensioni non consentite sulla puleggia.
(catalogo, distinta tecnica).
Equilibrio: vedere specchietto dellalbero o targhetta dei dettagli di
prestazione (H = mezza chiavetta, F = equilibrio chiavetta piena, N =
equilibratura senza chiavetta di aggiustamento)
DIN IEC ISO 8821. Nel montaggio degli elementi della trasmissione
tener conto dellequilibrio!
In caso di impiego o immagazzinaggio allaperto, viene consigliata
una copertura supplementare o un posizionamento rialzato da terra
in modo che venga evitata una esposizione prolungata ed intensa ai
raggi diretti del sole ed inoltre a pioggia, neve, ghiaccio e polvere.
In caso di estremit dellalbero rivolta verso lalto si devono evitare
infiltrazioni di acqua lungo lalbero.
5 Collegamento elettrico
Qualunque operazione sullimpianto deve essere affidata a personale

addestrato. Il motore deve essere disattivato e isolato. Assicurarsi
che non sia possibile una reinserzione accidentale. Detti
provvedimenti hanno validit anche per quanto riguarda i circuiti
ausiliari (es. scaldiglie).
Verificare lassenza di tensione!
Il superamento dei valori di tolleranza indicati in EN 60034, parte 1
/ IEC 34-1 (tensione 5%, frequenza 2%, forma e simmetria della
curva sinusoidale) comporta un aumento del riscaldamento e
influenza la tolleranza elettromagnetica). Osservare i dati di targa e lo
schema circuitale contenuto nella scatola collegamenti.
Lallacciamento deve essere effettuato in modo tale da garantire un
collegamento elettrico duraturo e sicuro (evitare che vi siano
estremit sporgenti di fili ). Effettuare collegamenti di protezione!
Coppie di serraggio per i collegamenti con la morsettiera, vedere Fig.
1.
Traferi tra le parti nude in tensione e verso terra 5,5 mm (UN
690 V).
Nella scatola collegamenti non devono essere presenti n corpi
estranei, n sporcizia o umidit.
Per le introduzioni nella scatola di giunzione (vedere DIN 42925),
ulteriori introduzioni aperte devono essere chiuse con una
guarnizione ad anello OR o una guarnizione piatta adeguata, e la
scatola di giunzione stessa deve essere chiusa con la guarnizione
originale e resa in tal modo stagna alla polvere e allacqua.
Coppie di serraggio per collegamenti a vite per cavi, vedere Fig. 2.1,
per altri tipi di avvitamento vedere Fig. 3.
In funzionamento di prova senza elementi condotti assicurare la
chiavetta.
Nel caso di motori dotati di freno, verificarne il funzionamento prima
della messa in servizio.
6 Esercizio
Intensit di vibrazione nellordine di veff 3,5 mm/s (PN 15 kW) o

veff 4,5 mm/s (PN > 15 kW) con funzionamento senza giunto sono
trascurabili.
Qualora si dovessero verificare anomalie rispetto allesercizio normale
(aumento della temperatura, rumori, vibrazioni), si raccomanda di
disinserire il motore. Verificare la causa delle anomalie e interpellare
eventualmente il costruttore. Non disinserire mai i dispositivi di
protezione, nemmeno in funzionamento di prova.
Nel caso di forte sporcizia, pulire regolarmente le condutture di
areazione. Aprire periodicamente i fori per lo scarico della
condensa!
Indipendentemente dalle ore desercizio di un motore, a causa della
riduzione del potere lubrificante il cuscinetto a rotolamento dovrebbe
essere sostituito ogni 3 anni circa.
Nel caso di motori senza dispositivi di ingrassaggio, attenersi alle
istruzioni del costruttore. Il reingrassaggio da effettuarsi comunque
al pi tardi dopo 3 anni.
In caso di motori senza dispositivo di rilubrificazione, sostituzione
del cuscinetto o del lubrificante secondo le indicazioni del produttore,
al pi tardi tuttavia dopo 3 anni.
In caso di motori con dispositivo di rilubrificazione, rispettare le
indicazioni riportate sulla targhetta della lubrificazione o su quella
con i dati sulle prestazioni. La rilubrificazione dovrebbe avvenire a
motore in funzione.
Nel caso di motori con cuscinetti volventi a cilindri, concepiti per
elevati carichi radiali, lesercizio con un carico radiale inferiore a
quello minimo provoca danneggiamenti. Il carico radiale desercizio
dovrebbe essere almeno pari al 30 % del carico radiale ammesso (si
veda il catalogo).
L'esercizio di motori a ventilazione forzata solo consentito con il
ventilatore esterno acceso.
7 Informazioni supplementari
Osservare le informazioni su eventuali dispositivi aggiuntivi come, p.

es., le diverse indicazioni dei produttori relative ai collegamenti a vite
dei cavi, elementi di tenuta inclusi.
Informazioni pi dettagliate sono contenute nelle istruzioni per
lesercizio e la manutenzione. Vi saranno inviati a richiesta se
indicherete il tipo e il numero dellapparecchio oppure si possono
consultare nel sito www.siemens.com/motors
Conservare con cura queste istruzioni!
SVENSKA
1 Allmnt
Elmotorer har farliga, spnningsfrande och roterande delar samt ev.

heta ytor. Allt arbete i samband med transport, anslutning,
idrifttagning och regelbundet underhll mste utfras av
kvalificerade, ansvariga yrkesmn (VDE 0150; IEC 364).
Osakkunnig hantering kan medfra svra person- och
materialskador. Uppmrksamma gllande svenska, lokala och
anlggningsspecifika bestmmelser och krav.
2 Avsedd anvndning
Dessa motorer r avsedda fr yrkesmssig anvndning. De uppfyller
kraven i de harmoniserade standardena i serien EN60034 (VDE
0530). De fr inte anvndas i explosionshotade utrymmen (Exomrden) om de inte uttryckligen sgs vara avsedda fr detta (se
kompletterande anvisningar). Om speciellt skrpta krav stlls i ngot
speciellt fall vid icke yrkesmssig anvndning - t.ex. krav p skydd
mot berring av barn - s skall anvndaren se till att dessa villkor
uppfylls p installationsplatsen.
Motorerna r dimensionerade fr omgivningstemperaturer mellan 20C och +40C och installationshjder 1000 mh. Om mrksylten
ger annan information, s ta ovillkorligen hnsyn till denna.
Frhllandena p installationsplatsen mste i alla avseenden stmma
med uppgifterna p mrkskylten.
Lgspnningsmotorer r komponenter fr montering i maskiner
enligt maskindirektivet 89/392/EEC. De fr inte tas i drift frrn
verensstmmelse med detta direktiv har dokumenterats
(beakta EN 60204-1).
SV
5 Elektrisk anslutning
Allt arbete skall utfras av kvalificerade yrkesmn med motorn
stillastende, frnkopplad och lst mot oavsiktlig terinkoppling.
Detta gller ven hjlpstrmkretsar (t.ex. stillestndsuppvrmning).
Kontrollera att anslutningen r spnningsls!
Om toleranserna i EN 60034 del 1 / IEC 34-1 verskrids - dvs.
spnning 5%, frekvens 2%, symmetrisk karakteristik - s verhettas
motorn och vllar starkare elektromagnetiska strningar. Ta hnsyn
till mrkskyltens uppgifter och kopplingsschemat i uttagsldan.
Motorn mste anslutas s att en varaktig plitlig elektrisk frbindelse
erhlls (inga utstickande trdndar). Anvnd lmplig skoning p
kabelndarna. Ordna plitlig anslutning av skyddsledare.
tdragningsmoment fr klmanslutningar, se fig1.
Luftgap mellan blanka, spnningsfrande delar sinsemellan samt
mellan dessa delar och jord 5,5 mm (UN 690 V) .
I uttagsldan fr det inte frekomma frmmande partiklar, smuts
eller fukt. Frslut anslutningar i kopplingsskp (se DIN 42925) och
vriga ppna anslutningar med O-ring eller annan lmplig ttning.
Sjlva kopplingsskpet skall vara frslutet damm- och vattentt med
originalttning.
tdragningsmoment fr kabelanslutningar, se fig 2.1, vriga skruvar,
se fig 3.
Fixera axelkilen fre provkrningen. P motorer med broms mste
man kontrollera att bromsen fungerar innan motorn startas.
6 Drift
3 Transport, frvaring
Om skador som registreras efter leveransen ska transportfretaget
omgende infomeras om detta; eventuellt mste idrifttagandet
skjutas upp. I samband med en transport mste alla lyftglor p
motorn anvndas, drag t iskruvade glor ordentligt! Dessa glor r
endast konstruerade fr motorns vikt, transportera allts inga andra
laster med dem. Om det behvs kan ven andra lmpliga
transportdon (t.ex linor) anvndas.
Ta bort transportskringarna innan motorn stts i drift. Stt tillbaka
dem igen om motorn skall flyttas.
Motorerna kan frvaras i torr och dammfri omgivning utan strre
vibrationer (veff 0,2 mm/s) fr undvikande av stillestndskador p
lagren. Vid lngre frvaringstid reduceras lagerfettets livslngd.
Om maskinen lagras lngre n 12 mnader mste fettets tillstnd
kontrolleras. Om man i samband med denna kontroll mrker att fettet
r frorenat (om kondensvatten trnger in frndras fettets
konsistens) mste fettet bytas ut.
Isolationsmotstnd
Det minsta isolationsmotstndet hos nya, rengjorda eller
reparerade lindningar uppgr till 10 M mot jord.
Mt isolationsmotstndet fre idrifttagningen.
Vid vrden 0,5 M/kV mrkspnning skall lindningen torkas.
Vibrationer upp till veff 3,5 mm/s (PN 15 kW) resp. veff 4,5 mm/s
(PN > 15 kW) kan godtas vid direkt pkoppling p axeln.
Stoppa motorn om avvikelser frn normal drift iakttas - t.ex. frhjd
temperatur, buller, vibrationer. Faststll orsaken och ta ev. kontakt
med tillverkaren. Stt inte skyddsanordningar ur funktion, inte heller
vid provkrningen.
Rengr luftkanalerna regelbundet om miljn r starkt frorenad.
ppna kondensvattenhlen d och d!
Oberoende av antalet drifttimmar br rullagret i en motor som

anvnds bytas ut ungefr vart 3:e r p grund av att smrjfrmgan
reduceras med tiden.
P motorer utan eftersmrjningsanordning ska lagret resp fettet
bytas ut enligt tillverkarens uppgifter, senast emellertid efter 3 r.
P motorer med eftersmrjningsanordning ska alla uppgifter p
smrjskylten eller effektskylten beaktas! Eftersmrjningen ska ske
medan motorn r igng!
P motorer med cylinderrullager fr hgre radiell belastning kan
motorn ta skada, om den krs med mindre belastning n den
minimalt tilltna radiella belastningen. Den radiella belastningen br i
drift uppg till minst 30% av den tilltna radiella belastningen (se
katalogen).
Nr en motor har exern flkt mste denna vara inkopplad
4 Installation
Iskruvade lyftglor skall dras t ordentligt eller avlgsnas efter tillsammans med motorn.
uppstllningen!
7 vrig information
Montera motorn p ett jmnt underlag med plitlig faststtning av
Beakta informationerna om eventuell extra utrustning, som t ex
foten eller montageflnsen. Rikta upp axeln omsorgsfullt vid direkt
anvisningarna frn respektive tillverkare vad det gller
pkoppling. Undvik installation som innebr resonans med
kabelfrskruvningar inklusive ttningselement!
trefasfrekvensen eller dubbla ntfrekvensen. Vrid rotorn fr hand och
vriga uppgifter finns i vra utfrliga
driftsoch
lyssna efter skrapande ljud. Kontrollera rotationsriktningen innan
underhllsinstruktioner. Meddela oss maskinens typ och nummer s
motorn kopplas p det drivna systemet (se Avsnitt 5).
versnder vi de till Er. Ni har ocks mjlighet att hmta de p
Drivdon (remskiva, koppling, etc.) skall dras p och tas av med
www.siemens.com/motors
lmpliga verktyg (uppvrmning) och frses med berringsskydd.
Frvara dessa skerhets- och driftsanvisningar fr framtida bruk!
Undvik otilltna remspnningar (se katalog, tekniska data)
Balanseringstillstndet r angivet p axelndytan eller p typskylten
(H = Halv-, F = Fullkilsbalansering, N = Balansering utan passkil). DIN
IEC ISO 8821. Observera balanseringstillstndet vid montering av
drivningen!
Vid anvndning eller lagring utomhus rekommenderas en
verbyggnad eller en extra kpa, s att en lngtidsinverkan vid direkt
intensiv solstrlning, regn, sn, is eller damm undviks.
Kontrollera att inte vatten trnger in i upptmonterad axeltapp.
Frhindra inte ventilationen! Frnluft fr inte kunna sugas in igen,
inte heller frn intilliggande aggregat.
CS
esky
elektromagnetick vlastnosti. Dbt na daje vkonovho ttku a
Elektromotory maj nebezpen, vodiv a rotujc sousti a ppadn schema pipojen ve svorkovnici.
hork povrchy. Je teba, aby vechny prce pi doprav, zapojovn, Pipojen se mus provst tak, aby bylo dosaeno trvale
uvdn do provozu a pravideln drb provdl kvalifikovan, bezpenho, elektrickho spojen (bez odstvajcch konc drt):
zodpovdn, odborn personl (dbt na VDE 0105, IEC 364). pouvat pslun kabelov koncovky. Vytvoit bezpen spojen
Neodborn jednn me zpsobit tk osobn a vcn kody. Je ochrannho vodie.
teba brt ohled na pslun platn nrodn, mstn a pro zazen Utahovac momenty pro ppoje na svrac desce viz. Fig. 1.
Veobecn
specifick ustanoven a poteby.
Vzdun vzdlenosti mezi holmi dly pod naptm navzjem a mezi

tmito dly a zem 5,5 mm (UN 690 V) .
Pouvn podle uren
Tyto motory jsou ureny pro prmyslov zazen. Odpovdaj

pslunm normm ady EN60034 (VDE 0530). Pouvn ve
vbunch prostorech je zakzno, pokud nejsou pro n vslovn
ureny (dbt na dodaten pokyny). Pokud ve zvltnm ppad - pi
pouit v neprmyslovch zazench - jsou kladeny zven
poadavky (nap. dotykov ochrana proti dtskm prstm), je teba
tyto podmnky zajistit pi instalaci ze strany zazen.
Motory jsou dimensovny pro teploty okol od -20C do +40C a
vku instalace 1000 m n. m. Bezpodmnen dbt na odlin
daje na vkonovm ttku. Podmnky v mst instalace mus
odpovdat vem dajm vkonovho ttku.
Nzkonapov motory jsou komponenty pro mont do stroj ve
smyslu strojrensk smrnice 89/392/EWG. Uvdn do provozu
je zakzno a do okamiku, kdy bude potvrzen soulad konenho
vrobku s touto smrnic (dbt na EN 60204-1).
Doprava, uskladnn
Ve svorkovnicch nesmj bt dn ciz tlesa, neistota a vlhkost.

Prchody v ppojnm pouzde (viz. DIN 42925), dal voln
prchody se mus uzavt O-kroukem nebo jinm vhodnm plochm
tsnnm. Ppojn pouzdro samotn se mus uzavit vodo- a
prachotsn originlnm tsnnm
Utahovac momenty na kabelovch roubech viz. Fig. 2.1, pro ostatn
rouby viz. Fig. 3.
Pi zkuebnm chodu bez pohncch prvk zajistit pero.
U motor s brzdou ovit ped uvedenm do provozu bezvadnou
funkci brzdy.
Funkce
Intensity chvn veff 3,5 mm/s (PN 15 kW), pop. veff 4,5 mm/s (PN
> 15 kW) nejsou ve spaenm provozu na zvadu.
Pi zmn vi normln funkci - nap. zvench teplotch, hluku,
vibracch - je teba v ppad pochybnost motor odpojit. Zjistit
pinu, ppadn dotaz u vrobce. Bezpenostn zazen
nevyazovat z funkce ani pi zkuebnm provozu.
Pi silnm vskytu neistot pravideln istit vzduchov cesty.
Existujc uzaven otvory pro kondensovanou vodu as od asu
otevt!
Nezvisle na potu provoznch hodin provozovanho motoru by se
mlo valiv loisko v dsledku snen mazivosti kad ti roky
obnovit.
U motoru bez pimazvacho zazen vmna loisek nebo tuku
podle daj vrobce, nejpozdji ale po 3 letech.
U motor s domazvacm zazenm je teba dodrovat daje na
mazacm ttku nebo vkonnostnm ttku! Domazn se mus
provdt pi motoru v chodu!
U motor s cylindrickmi vlekovmi loisky pro zven radiln
zaten jsou pi provozu s menm ne minimlnm radilnm
zatenm zpsobeny kody. Radiln zaten by mlo pi provozu
init minimln 30 % povolenho radilnho zaten (viz katalog).
U motor s externm ventiltorem mus bt ventiltor za provozu
motoru trvale zapnut.
Po expedici stanoven pokozen ihned oznamte dopravci, uveden

do provozu pop. vylouit. Pi peprav mus bt pouita vechna
zvsn oka na motoru, zaroubovan pevn uthnout! Tato jsou
dimenzovna pouze pro hmotnost motoru, nepipevovat dnou
dodatenou zt. Pokud je to nutn, pouvat vhodn, dostaten
dimenzovan pepravn prostedky (nap. veden lana).
Ped uvedenm do provozu odstranit pouit dopravn zajitn.
Pi dalm transportu je znovu pout. Maj-li bt motory uskladnny,
dbt na such, bezpran a bezotesov (veff 0,2 mm/s) prosted
(kody zpsoben skladovnm). Pi delm skladovn se sniuje
ivotnost tuku v loiscch.
Pi skladovn nad 12 msc je poteba provst kontrolu stavu tuku.
Pokud je kontrolou tuku zjitno zneitn tuku (vniknut
kondenzan vody vede ke zmn konzistence tuku), mus bt tuk
vymnn.
Izolan odpor
Minimln izolan odpor novch a oitnch vinut nebo vinut po
drb proti koste je 10 M. Ped uvedenm do provozu zmit
Dal informace
isolan odpor. U hodnot 0,5 M/kV dimenzovaneho napt je 7
Zohlednte informace o ppadnch doplkovch zazench, jako
teba vysuit vinut.
napklad rzn pokyny vrobc kabelovch roubovch spojen
vetn tsnicch prvk!
4
Instalace
Naroubovan zvsn oka je teba po instalaci pevn dothnout
nebo odstranit!
Dbt na sprvn uloen, dobr upevnn patek nebo pruby a
pesn vyrovnn u pmho spojen. Vylouit rezonance s frekvenc
otek a dvojitou sovou frekvenc zpsoben instalac. Rotor
protoit rukou, dbt na neobvykl tec hluk. Zkontrolovat smr
oten v nepipojenm stavu (dbt na odst. 5).
Pohnc prvky (emenice, spojka ...) stahovat a nasazovat pouze
vhodnmi ppravky (oht!) a zakrt protidotykovm krytem. Vylouit
neppustn napnut emene (katalog, techn. nvod).
Vyvaovac stav viz tabulky hdele nebo vkonov ttek (H =
napolo, F = pln klnov vyveno, N = vyveno bez zalcovanho
pera) DIN IEC ISO 8821. Pi monti prvku pohonu pozor na
vyvaovac stav!
Pi pouit nebo skladovn pod irm nebem se doporuuje
nstavba nebo dodaten zakryt tak, aby se pedelo
dlouhodobmu psoben pmho intenzivnho slunenho zen,
det, snhu, ledu nebo tak prachu.
Pi svisl poloze hdele se mus dbt nato, aby na hoejm konci
voda nemohla vniknout podl hdele.
Nebrnit ventilaci! Vystupujc vzduch - i sousednch agregt - se
nesm bezprostedn opt nasvat.
Dal podrobnosti obsahuj nae podrobn provozn a drbov

pokyny. Po zadn typu a sla stroje Vm budou tyto na pn
zaslny, nebo jsi je mete vyhledat na adrese
www.siemens.com/motors
Tyto pokyny o bezpenosti a uveden do provozu je teba
uchovvat!
Elektrick pipojen
Vechny prce smj bt provdny jen kvalifikovanm odbornm

personlem na motoru v klidu ve vypnutm a proti optovnmu
zapnut zajitnm stavu. To plat tak pro pomocn proudov
okruhy (nap. klidov ohev).
Ovit neptomnost napt!
Pekroen toleranc EN60034, dl 1/IEC 34-1 - napt 5%,
frekvence 2%, tvaru kivky, symetrie - zvyuje oteplen a ovlivuje
13
Fig. 1
DE
EN
FR
ES
IT
SV
NL
PT
Anziehdrehmomente fr Schraubenverbindungen der elektrischen Anschlsse - Klemmenbrettanschlsse (auer Klemmenleisten)

Tightening torques for screwed connections for the electrical terminals - terminal board connections (apart from terminal strips)
Couples de serrage pour raccords vis des connexions lectriques - raccords de tablette bornes (sauf barrettes de raccordement)
Momentos de par de apriete para las atornilladuras de las conexiones elctricas conexiones del tablero de bornes (excepto regletas de bornes)
Coppie di serraggio per i raccordi a vite degli allacciamenti elettrici allacciamenti alla morsettiera (eccetto listelli di raccordo)
tdragningsmoment fr de elektriska anslutningarnas skruvanslutningar klmanslutningar (utom klmlister)
Aantrekmomenten voor schroefverbindingen van de elektrische aansluitingen klembordaansluitingen (behalve klemlijsten)
Momentos de aperto das unies aparafusadas das ligaes elctricas ligaes da placa de bornes (rguas de bornes exteriores)
EL
- ( )
DA
FI
S
HU
SL
SK
PL
ET
LV
LT
MT
Tiltrkningsdrejningsmomenter tilskrueforbindelser af elektriske tilkoblinger klemmebrttilkoblinger (uden klemmelister)

Shkliitntjen ruuviliitosten - pinnelevyliitntjen (paitsi liitinkiskojen) vntmomentit
Utahovac momenty pro roubov spojen elektrickch ppoj ppoj na svorkovnici (mimo svracch lit)
Az elektromos rintkezk csatlakoztbla csavaros bektseinek meghzsi nyomatkai (kivve a szortsvot)
Pritezni navori za elektrine prikljuke povezave na prikljuni ploi (razen prikljunih trakov)
Uahovacie momenty skrutkovanch spojov pre elektrick svorkovnice dosky spojov svorkovnice (veda psov svorkovnice)
Momenty docisku przykrcanych poacze wyprowadze elektrycznych poczenia tablicy rozdzielczej (poza listw zaciskow)
hendusklemmide kruviliidete pingutusmomendid klemmikarbihendused (vlimised hendusklemmid)
Elektrospaiu skrvjamo savienojumu savilces griezes momenti spaiu plates savienojumi (neskaitot spaiu sloksnes)
Elektrini kontakt sukt sujungim suverimo jga ryiams ivad skydelyje (iskyrus kontakt skydams)
It-torque ta l-issikkar gal konnessjonijiet invitati gat-terminali ta l-elettriku konnessjonijiet terminali tal-bord
(barra mill-istrippi terminali)
DE - Gewinde
FI - Kierre-
EN - Thread-
CS - zvitu
FR - du filetage
HU - Menet-
ES - de la rosca
SL - Navoj-
IT - Diametro del filetto
SK - Zvit-
SV - Gngdimeter
PL - Gwint
NL - Schroefdraad-
ET - Keere
PT - rosca-
EL -
LT - Sriegis
M4 M5 M6 M8 M10 M12 M16
LV - Vtne
DA - Gevind-
MT - Hajta
DE - Anziehdrehmoment
FI - Vntmomentti
EN - Tightening torque
CS - utahovac moment
FR - Couple de serrage
HU - Meghzsi nyomatk
ES - Momento de par de apriete
SL - Pritezni navor
IT - Coppia di serraggio
SK - Uahovac moment
SV - tdragningsmoment
PL - Moment docisku
min
E.
Min.
0,8
1,8
2,7
5,5
14
27
1,2
2,5
13
20
40
Lgmark
Nm
NL - Aantrekmomenten
ET - Pingutusmoment
PT - Momento de aperto
LV - Savilces griezes moments
EL - E
DA - Tiltrkningsdrejningsmoment
LT - Uverimo jga
maks.
MT - Torque li jissikka
Hmark
max
FIG. 2
DE - Ausschlagen der ffnungen fr Kabel und Leitungen im Anschlukasten
BG 100...160L (1LA7/9,
EN - Knocking out the openings for cables and leads in the terminal box
FR - Rupture des membranes de fabrication aburant les entes de cbles et de
conducteurs sur la bote bornes
ES - Martillando las aberturas pasacables de la caja de bornes
IT - Asportare la pellicola per cavi e conduttori nella cassetta terminale
SV - Utslagning av ppningarna fr kabel och ledningar i uttagsldan
NL - Het uitslaan van openingen voor kabels en leidingen in de aansluitkast
PT - Romper as passagens para cabos e condutores na caixa de ligao
EL -
DA - Udslning af bningerne til kabler og ledninger i kabelkassen
FI - Liitntlaatikon aukot lydn auki johtoja varten
CS - Vyraen otvor pro kabely a veden ve svorkovnici
HU - A csatlakozdoboz kbel s vezetknylsainak megnyitsa a
zrdugk kitsvel
SL - Izbijanje odprtin za kable in prikljuke v prikljuni katli
SK - Vyrazenie otvorov pre kble a vedenia v skrini svorkovnice
DE - Ausbrechffnung (Guhaut)
PL - Wybijanie otworw na kable i przewody w puszce rozdzielczej
EN - Cast iron skin
FR - Membrane de fabrication
ET - Klemmikarbi lbiviiguavade avamine
ES - Membrana de fundicin
LV - Kabeu un pievadu atveru izsiana spaiu krb
IT - Pellicola residua della colata
LT - Skyli igrimas kabeliams ir viesos diodams kontakt blokelyje
SV - Gjutskorpa
MT - armar tal-ftu ta kejbils u wajers minn ol-kaxxa tal-kurrent
1LP7/9, 1PP7/9)
NL - Het uitbreken van een opening (giethuid)

PT - Passagem (crosta de fundio) a romper
EL - ( )
DA - bning til at trykke ud (Stbehud)
FI - Irtimurrettava aukko (valupinta)
CS - Vylamovac otvor (epika)
HU - ntttvas bevonat
SL - katla iz elezne litine
SK - Odlievan kovov povrch
PL - Powoka metalowa
ET - Metallkesta ettevaltsitud (suletud) avad
LV - uguna apvalks
LT - Nulupkite gelein apvalkal
MT - Qoxra tal-fondut
22
FIG. 2.1
DE
EN
FR
ES
IT
SV
NE
PT
- Anziehdrehmoment der Kabelverschraubungen aus Metall (*) und Kunststoff (**) fr direkten Anbau am Motor.
Bei weiteren Verschraubungen (z. B. Reduzierungen) sind die entsprechenden Momente gem Tabelle anzuwenden.
- Tightening torques of the cable screw connections made from metal (*) and plastic (**) for direct installation on the motor.
For other threaded attachments (e.g. reducers) the appropriate torques in the tables are to be used.
- Le couple de serrage des passe-cble vis en mtal (*) et en plastique (**) pour le montage direct sur le moteur.
Pour les autres raccords vis (par ex. rductions), il faut utiliser les couples correspondants indiqus dans le tableau.
- Par de apriete de los racores para cables en metal (*) y plstico (**) para el montaje directo en el motor.
Tratndose de otras atornilladuras (p.ej., reductores), se tienen que aplicar los pares correspondientes de conformidad con el cuadro.
- Coppia di serraggio dei collegamenti a vite dei cavi in metallo (*) e materiale sintetico (**) per il montaggio diretto sul motore.
In caso di altri collegamenti a vite (p. es. riduzioni), applicare i momenti riportati nella tabella.
- tdragningsmoment fr kabelfrskruvningar av metall (*) och plast (**) fr direkt montering p motorn.
Fr vriga frskruvningar (t ex reduceringar) gller de i tabellen angivna tdragningsmomenten
- Aanhaalkoppel van de kabelschroefverbindingen van metaal (*) en kunststof (**) voor de directe montage aan de motor.
Bij andere schroefverbindingen (bijv. reducties) dienen de desbetreffende koppels conform de tabel te worden gebruikt.
- Binrios de aperto dos acoplamentos roscados de metal (*) e material sinttico (**) para a montagem directa no motor.
Para os outros acoplamentos roscados (p.ex., redues) devem ser empregados os respectivos binrios, de acordo com a tabela.
EL
- (*) (**) .
(.. ) .
DA
- Startmoment for kabelforskruninger af metal (*) og kunststof (**) for direkte tilbygning til motor.
Ved vrige forskruninger (f.eks. reduceringer) anvendes momenterne i henhold til tabel.
- Kaapelien metallisten (*) ja muovisten (**) kierreliitntjen kiristysmomentit asennettaessa suoraan moottoriin.
Muille kierreliitnnille (esim. supistusosille) on kytettv vastaavia momentteja taulukon mukaan.
- Utahovac toiv moment kabelovch roubovch spojen z kovu (*) a plastu (**) k pm monti na motor.
U dalch roubovch spojen (napklad redukc) pouijte pslun momenty uveden v tabulce.
- A kbel fm (*) s manyag (**) csavarktseinek meghzsi nyomatkai kzvetlenl a motoron.
A tbbi alkatrsz (pl. reduktorok) csavarmenetes rgztsnl a tblzatban megadott meghzsi nyomatkokat kell alkalmazni.
- Pritezni navori za vijane kabelske prikljuke iz kovine (*) in plastike (**) za neposredno namestitev na motor.
Za druge navojne prikljuitve (kot so reduktorji) so ustrezni navori prikazani v tabeli.
- Uahovacie momenty pre skrutky kblovch spojov vyroben z kovu (*) alebo umelej hmoty (**) pre priamu intalciu motora.
Pre alie skrutkovan doplnky (napr. redukcie) s pouit zodpovedajce momenty uveden v tabukch.
- Momenty docisku przykrcanych pocze kabli z metalu (*) i plastiku (**) do bezporedniej instalacji w silniku.
Dla innych pocze gwintowych (np. reduktorw) naley stosowa odpowiednie momenty podane w tabeli.
- Pingutusmomendid kaablite metallist (*) ja plastist (**) kruvihenduste jaoks otse mootorile paigaldamiseks.
Teiste keermeliidete (nt siirdemuhvid) puhul tuleb jrgida tabelites toodud sobivaid pingutusmomente.
- Metla (*) un plastmasas (**) kabeu skrvju savienojumu savilces griezes momenti, montjot tiei uz motora.
Citiem piederumiem ar vtni (piemram, reduktoriem) ir jlieto tabul nordtais atbilstoais griezes moments.
- Kabelio verls sujungim, pagamint i metalo (*) ir plastiko (**) uverimo jga diegimui variklyje.
Kitiems sriegio prijungimams (pavyzdiui, reduktoriams) naudojama atitinkama lentelse nurodyta uverimo jga.
- Torques ta l-issikkar tal-konnessjonijiet invitati ta kejbil magmula minn metall (*) u plastik (**) gal installazzjoni diretta fuq ilmagna. Gal tagmir mijud li fih kamin (p.e ridjuser) it-torques xierqa fit-tabelli jridu jintuaw.
FI
S
HU
SL
SK
PL
ET
LV
LT
MT
(*)
(**)
DE - O-Ring-Dicke
FI - O-renkaan paksuus
EN - O-Ring-Thickness
CS - O-krouek
FR - Joint torique
ES - junta trica
HU - O gyr vastagsga
SL - Debelina tesnila
IT - Guarnizione a o-ring
SK - Hrbka O-krka
SV - O-ring
PL - Grubo O-Ring
NL - O-ring - dikte
ET - O-rngastihendi paksus
LV - Gredzena biezums
PT - Espessura de O-ring
Nm
M 12 x 1,5
M 16 x 1,5
M 25 x 1,5
M 32 x 1,5
M 40 x 1,5
M 50x 1,5
M 63 x 1,5
M 72 x 2
EL -
LT - O-iedo storumas
DA - O-ring tykkelse
MT - Hxuna ta' anell-O
Nm
min
4
5
6
max
6
7,5
9
12
10
14
min
max
mm
2
4
23
Fig. 3
DE
EN
FR
ES
IT
SV
NL
PT
Anziehdrehmomente fr Schrauben am elektrischen Anschlukasten, Lagerschilden und Schutzleiter-Schraubverbindungen

Tightening torques for screws at the electrical terminal box, end shields and screwed connections for protective conductors.
Couples de serrage pour vis - sur larmoire lectrique, .flasques et raccords vis de fils de protection
Momentos de apriete para los tornillos en la caja de conexiones elctricas, placas de los cojinetes y conexiones del conductor de
puesta a tierra y conexiones roscadas.
Coppie di serraggio per avvitamenti alla scatola di giunzione elettrica, scudi e collegamenti a vite del conduttore di protezione
tdragningsmoment fr skruvar p kopplingsskp, lagerskyltar och skyddsledaranslutningar
Aantrekmomenten voor schroeven aan de elektrische aansluitkast, opslagborden en beschermgeleider-schroefverbindingen
Momentos de aperto dos parafusos das caixas de terminais elctricas, das placas dos rolamentos e das unies aparafusadas dos
condutores de proteco.
,
.
Tiltrkningsdrejningsmomenter til skruer p den elektriske kabelkassen, lagringsplader ogpreltrd-skrueforbindelser
Shkliitntkotelon, laakerikilpien ja maadoitusjohtimien ruuviliitosten vntmomentit
Utahovac momenty roub v elektrickm ppojnm pouzde, loisek ve ttu a roubovch spojen na ochrannm veden.
A vdkbelek csavaros bektseinek meghzsi nyomatkai az elektromos csatlakozdoboznl s a zrpajzsoknl.
Pritezni navori za vijake v katli z elektrinimi prikljuki, konne itnike in vijane prikljuke za zaitne vodnike.
Uahovacie momenty pre skrutky na elektrickej svorkovnici, ukonenia krytov a skrutkovan spoje pre ochrann uzemnenia.
Momenty docisku rub w puszce rozdzielczej, oson kocwek oraz dokrcanych pocze przewodnikw zabezpieczajcych.
hendusklemmide kruviliidete, otsakaante ja kaitsemaandusjuhi kruvihenduste pingutusmomendid.
Elektrospaiu krbas skrvju, gala vciu un aizsargvadu skrvjamo savienojumu savilces griezes momenti.
Uverimo jga vartams elektrini kontakt blokelyje, skydams ir suveriamoms jungtims apsauginiuose konduktoriuose.
Torques ta l-issikkar gal viti li jinsabu fil-kaxxa tal-kurrenti elettrii, it-tarki ta protezzjoni li jinsabu fl-aar tal-wajers u
konnessjonijiet invitati gal kondutturi li jipproteu.
EL DA
FI
S
HU
SL
SK
PL
ET
LV
LT
MT
DE
EN
FR
ES
IT
SV
NL
PT
EL
DA
FI
S
HU
SL
SK
PL
ET
LV
LT
MT
DE - Gewinde
FI - Kierre-
EN - Thread-
CS - zvitu
FR - du filetage
HU - Menet-
ES - de la rosca
SL - Navoj-
IT - Diametro del filetto
SK - Zvit-
SV - Gngdimeter
PL - Gwint
NL - Schroefdraad-
EST - Keere
PT - rosca-
EL -
LV - Vtne
DA - Gevind-
MT - Hajta
DE - Anziehdrehmoment
EN - Tightening torque
FI - Vntmomentti
FR - Couple de serrage
HU - Meghzsi nyomatk
ES - Momento de par de apriete
SL - Pritezni navor
M4 M5 M6 M8 M10 M12 M16 M20
LT - Sriegis
min
E.
CS - utahovac moment
Min.
3,5
16
28
46
110
225
24
42
70
165
340
Lgmark
IT - Coppia di serraggio
SK - Uahovac moment
SV - tdragningsmoment
PL - Moment docisku
NL - Aantrekmomenten
ET - Pingutusmoment
PT - Momento de aperto
LV - Savilces griezes moments
maks.
EL - E
LT - Uverimo jga
Hmark
DA - Tiltrkningsdrejningsmoment
MT - Torque li jissikka
Nm
max
Die Anziehdrehmomente gelten soweit keine anderen Werte angegeben sind! Einwandfreie Werkzeuge sind zu verwenden!
The tightening torques apply where other values are not indicated! Use only tools that are in perfect condition!
Les couples de dmarrage ci-dessus sappliquent sauf indication dautres valeurs! Nutilisez que des outils en parfait tat de marche.
Los momentos de par de apriete son vlidos mientras no se indique otros valores! Es necesario utilizar herramientas en perfecto
estado!
- Le suddette coppie di serraggio sono valide fintanto che non vengono indicati altri valori! Devono essere utilizzati utensili in
perfette
condizioni!
- Ovanstende tdragningsmoment gller om ej andra vrden angivits! Anvnd felfria verktyg
- Inzoverre geen andere waarden zijn vermeld, gelden de aantrekmomenten! Er moeten onbeschadigde werktuigen worden
gebruikt!
- Os momentos de aperto indicados so vlidos, desde que no se indiquem valores diferentes! Utilizar sempre ferramentas em
bom estado!
- . .
- Tiltrkningsdrejningsmomenterne glder for s vidt det er ikke opgitt andre vrdier! Det skal bruges upklagelige vrktj!
- Vntmomentit ovat ptevi mikli muita arvoja ei ole ilmoitettu! Kyt virheettmi tykaluja!
- Utahovac momenty plat, pokud nejsou udny jin hodnoty! Pouvejte jen bezvadn nad!
- A meghzsi nyomatkokat akkor kell alkalmazni, ha ms rtkek nem lettek megjellve! Csak hibtlan llapot szerszmot
szabad hasznlni!
- Pritezni navori veljajo povsod, kjer druga vrednost ni naznaena! Uporabljajte le brezzihna orodja!
- Uahovacie momenty pouite tam, kde nie s uren in hodnoty! Pouvajte iba nradie vo vbornom stave!
- Te momenty docisku obowizuj tam, gdzie nie podano innych wartoci! Naley uywa wycznie narzdzi w doskonaym stanie
technicznym!
- Need pingutusmomendid kehtivad juhul, kui vrtused on jetud mrkimata! Kasutage ainult tiesti korras triistu!
- ie savilces griezes momenti jlieto, ja nav nordtas citas vrtbas! Izmantojiet tikai nevainojam stvokl esous rkus!
- Pateikta uverimo jga tinkama tik tada, kai kitos verts nenurodytos! Naudokite tik tvarkingus rankius!
- It-torques ta l-issikkar japplikaw fejn valuri ora mhumiex indikati! Ua biss godda li tinsab fkundizzjoni perfetta.
Automation & Drives

Standard Drives
D-91056 Erlangen
nderungen vorbehalten / Subject to change without prior notice
Siemens Aktiengesellschaft
DE / EN / FR / ES / IT / SV / NL / PT / EL / DA / FI / S / HU / SL / SK / PL / ET / LV / LT / MT
24
Bestell-Nr. / Order No.: 5 610 70000 38 006

Printed in the Federal Republic of Germany
06.04
24
Specification of procedure

for boiler and system components
G012
Version 1 (09/04)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Wet conservation ......................................................................................................................................................... 3
6.1.1
Conservation with the oxygen binder sodium sulphite (Na2SO3).................................................................................. 3
6.1.2
Setting up the necessary pH-value .............................................................................................................................. 3
6.1.3
Use of other dosing agents .......................................................................................................................................... 4
6.1.4
Carrying out the conservation ...................................................................................................................................... 4
6.1.5
Measures during the down time ................................................................................................................................... 4
6.2
Re-connexion after conservation.................................................................................................................................. 4
6.3
Dry conservation .......................................................................................................................................................... 5
6.3.1
Overview of drying agents............................................................................................................................................ 5
6.3.2
Carrying out the conservation ...................................................................................................................................... 5
6.3.3
Measures during the down time ................................................................................................................................... 6
6.4
Re-connexion after conservation.................................................................................................................................. 6
6.5
Alternative methods...................................................................................................................................................... 6
Technical Data (Dimensions, Weight, Operating Conditions) ................................................................................ 6
10
Page 1 of 7

G012
Version 1 (09/04)
Incoming oxygen from the air is corrosive in cooled boiler or system components which are not under pressure. Suitable
measures therefore need to be taken. These Operating Instructions describe the basic principles for the conservation of
boiler or system components with planned down times of > 1 week.
The operator of the plant, and not the manufacturer, is responsible for personal injury and material damage caused by use
that is not in accordance with regulations.
Safety
The personnel responsible for conservation must be familiar with handling the chemicals in question. The products must be
handled with care. Personnel must be familiar with suitable first-aid measures.
The conservation of boiler or system components, especially the wet conservation, is generally associated with the use of
various chemicals.
It is vital that the precautionary measures according to the safety data sheets for the various chemicals used are followed,
especially the references to the particular dangers and the advice on safety according to the Order on Dangerous
Substances.
Caution! Failure to observe the regulations may cause damage to health and to the environment.
Page 2 of 7

G012
Version 1 (09/04)
6.1
Wet conservation
Wet conservation is generally recommended when the down time is limited (generally in the range of > 1 week and < 3
months) and relatively fast restarting of the boiler or system components is required.
The wet conservation process is not suitable if there is a risk that the boiler or system components will be exposed to frost
during the conservation period. In this case, the boiler or system components are to be dry conserved (see Section 6.2).
6.1.1
Conservation with the oxygen binder sodium sulphite (Na2SO3)
Sodium sulphite is added as an oxygen binder during conservation. The sulphite content in the conservation solution
depends on the length of the down time and the nature of the filling water.
Important! Traditional sodium sulphite only reacts at temperatures above approx. 40C. This is sufficient for
dosing in normal boiler operation. For conservation, on the other hand, a special catalyzed Na2SO3 should be
used which binds oxygen at low temperatures.
Filling water
Length of down
time
Sodium sulphite
content
pH value
mg Na2SO3/l
low-salt or salt-free
1 week
20 - 50
water, condensate
1 month
100 - 200
longer than 1 month
200 - 500
1 week
40 - 100
longer than 1 week
400 - 1000
water containing salt
10
11 - 12
For filling the boiler or system components (see Section 6.1.4), deaerated filling water according to our Operating
Instructions B002 Guideline on water characteristics, steam generator or B004 Guideline on water characteristics, hot water
boiler should preferably be used. Non-deaerated water contains approx. 10 g O2/m at 20C. Since 1 g of air oxygen is bund
by approx. 8 g standard commercial water-free sodium sulphite (pure substance), around 80 g Na2SO3 per m would need to
be added in addition if non-deaerated water is used for filling.
Sodium sulphite is available in powder form or as a liquid solution. The powder, which generally has a Na2SO3 content of
approx. 92-95%, must first be dissolved in the feed water or condensate (30-40C). An approx. 10% solution should be
used, i.e. 10 kg Na2SO3 to 90 l water. This must be carried out in a closed container, e.g. the existing dosing container.
Otherwise, the sulphite could react with the oxygen in the air during the dissolving process and thus become ineffective.
The use of liquid products is less problematic, since they can also be added directly from the container without any need to
produce a solution first. For this reason, the use of sodium sulphite in liquid form is recommended. The Na2SO3 solution may
have a different Na2SO3 content, depending on the manufacturer. The composition as given in the product description
should therefore be noted when determining the quantity to be added.
Important! If the boiler system has to be shut down, the operating and maintenance staff must be suitably
informed of this. In addition, a sign is to be affixed to the system and to the switchgear cabinet if necessary which
expressly points out that the system has been shut down and is thus not operational. This sign should also state
the time when the system was shut down and the name of the person who is allowed to start the system up
again or who may give the instructions for the start-up.
6.1.2
Setting up the necessary pH-value
If low-salt or salt-free filling water is used, the pH value must be at least 10, or at least 11-12 in the case of water containing
salt. The necessary alkalinity can be achieved by adding trisodium phosphate and/or soda lye.
Page 3 of 7

G012
Version 1 (09/04)
6.1.3
Use of other dosing agents
In addition to sodium sulphite, other dosing agents are available on the market which are recommended by the
manufacturers for conservation. These are generally strong oxidation agents, such as ascorbates or carbohydrazides.
Because of the suspicion that it may be carcinogenic and the associated official requirements laid down for its use,
hydrazine is generally no longer used for boiler conservation.
If dosing agents other than sodium sulphite are used, the instructions for use and safety recommendations issued by the
manufacturer must be noted in any case. Loos International offers no guarantee that these products are suitable or effective.
6.1.4
The following instructions apply in general for boiler or system components. The product-specific instructions for carrying out
conservation are described in detail in the Operating Instructions for the individual boiler or system components.
Before conservation, the boiler or system component must first be emptied and checked for existing corrosion. After this, the
boiler or system component must be completely refilled with water.
Filling must be carried out using prepared water in accordance with our Operating Instructions B002/B004 Guideline on
water characteristics, to which a sufficient quantity of dosing agent is added (see Sections 6.1.1 and 6.1.2).
All valves on the boiler or system component must then be closed tightly to prevent any penetration of air-borne oxygen
during the down time.
Important! The boiler or system component should only be sealed off once it has cooled down completely in
order to avoid negative pressure.
Important! With longer down times, the water content should be checked regularly (1 x week) to see that the pH
is sufficient and that there is surplus oxygen binder, and topped up if necessary.
Note: If there are no shut-off valves at the incoming and outgoing outlets of the boiler or system component, it
will be necessary to close these connections tightly using blanking plates, in the case of flange connections, or
screw plugs, in the case of threaded connections.
Note: If the wet preservation is carried out at outside temperatures of < 3C, suitable frost protection should be
provided in the boiler house.
6.1.5
Measures during the down time
The conservation solution should be analysed every 3 days for sodium sulphite surplus (or if another dosing agent is used,
the relevant surplus) and to determine the pH value. If the Na2SO3 surplus falls below the lower limit value according to the
above table, more sodium sulphite must be added.
To determine the sulphite surplus, you should use the special test sets or test strips for rapid testing recommended by the
manufacturers of the dosing agents (e.g. sulphite test made by Merck). The pH can be measured with a measuring device or
simple litmus paper.
6.2
Re-connexion after conservation
The following instructions apply in general for boiler or system components. The product-specific instructions for carrying out
conservation are described in detail in the Operating Instructions for the individual boiler or system components.
Because of the quantity of conservation agent added, the salt content of the conservation solution is too high for normal
operation. Care should therefore be taken to ensure, before restarting the boiler, that the values are as stated in Operating
Instructions B002/B004 Guideline on water characteristics. For this, the water should be completely drained off.
Page 4 of 7

G012
Version 1 (09/04)
After this, the system is to be refilled with prepared, suitably treated water and restarted as for a cold start.
When the conservation solution is drained off, the local regulations for draining waste water into the sewerage system must
be followed.
6.3
Dry conservation
Dry conservation processes are generally used with longer down times (> 3 months) if the boiler or system components do
not need to be started up again at short notice or wet conservation is not possible, because of the danger of frost, for
example.
6.3.1
Overview of drying agents
The easiest drying agents to handle are bags of drying agent with a defined absorption capacity (drying agent unit).
Silica gels are suitable for use as drying agents. Silica gels with an indicator dye are reliable in use. A change in the
colour shows that the absorption capacity of the material is exhausted.
Caution! The particularly well-known blue gel should not be used any more! Its blue indicator dye, cobalt
dichloride, has been classified as a Category 2 carcinogen and must be labelled with the danger phrase 49 (R
phrase) "Can cause cancer if inhaled".
As a rule, silica gels with safe moisture indicators free from heavy metals, e.g. silica gel orange.
It is also possible to use simple silica gel without a moisture indicator. To check its absorption capacity, there are
indicator cards which can be attached to the drying agent bags. These also change colour to show that the absorption
capacity is exhausted.
Activated clay (bentonite) is also a suitable drying agent. There are also special indicator cards for this product.
Other drying agents include, for example, calcium chloride and calcium oxide. However, since these are problematic to
handle, we advise against using them.
Dosage:
Approx. 500 g silica gel or 600 g drying clay, which is 16 drying agent units, as they are called, should be used per cubic
metre of the volume to be dried. Drying agent bags are available in standardised sizes, containing 16, 32 or 80 drying agent
units.
6.3.2
The Boiler or system components must be emptied completely. This should be carried out still in the warm (approx. 70 - 80
C) state if possible, so that the residual moisture is evaporated by the warmth still stored in the material.
If the residual warmth is not enough to evaporate the moisture, drying out can be supported by blowing in warm air.
It is essential that any coatings in which moisture could be bound or salt deposits must be removed before the preservation
measures.
Important! Drying agents are generally only suitable for the absorption of water in vapour form. Drying agents
may decompose if brought into contact with liquid water.
When the inside of the Boiler or system components is dry, flat containers filled with a drying agent are placed in the system.
The system is then sealed. The drying agent container should be positioned in such a way that no enclosed cavities can
form underneath them.
All valves on the boiler or system component must then be closed tightly to prevent any penetration of air-borne oxygen
during the down time.
Note: If there are no shut-off valves at the incoming and outgoing outlets of the boiler or system component, it
will be necessary to close these connections tightly using blanking plates, in the case of flange connections, or
screw plugs, in the case of threaded connections.
Page 5 of 7

G012
Version 1 (09/04)
6.3.3
Measures during the down time
If the drying agent is exhausted, it can generally be regenerated by heating (at 110 - 140C, depending on product, please
follow manufacturer's instructions). However, the absorption capacity is not completely restored in regeneration. It will be
approx. 90% of the original capacity.
The state of the drying agent should be checked every month, or every one to two weeks at the start of preservation. If the
unit has to be opened, and humidity from the air thus, the drying agent must be regenerated before the unit is closed again,
or fresh drying agent should be used.
It is also possible to use moisture indicators with a small viewing window which can be screwed into a threaded connection
piece, thus allowing monitoring from outside. However, there is a risk that these indicators are not representative, since they
are situated a long way from the drying agents, in a connection without air circulation.
6.4
Re-connexion after conservation
After the down time, the drying agents are removed and the system is checked for corrosion. Any blanking plates, with
flange connections, or screw plugs, in the case of threaded connections, are to be remove. The procedure is then the same
as for the initial start-up of the boiler or system component.
Note: The competent monitoring organisation should be consulted beforehand to clarify whether a new
acceptance procedure is necessary. The instructions in the safety data sheet should be followed with regard to
disposal of the drying agents.
6.5
Alternative methods
In principle, it is possible to fill the boiler after emptying with nitrogen or ammonia and in this way to expel the oxygen in the
air, which promotes corrosion, from the boiler. Ammonia will also ensure that any residual moisture left in the boiler becomes
alkaline. However, because of the large boiler capacities, large volumes of gas are required. With nitrogen in particular, the
oxygen content must be < 0.1%. This ultra-pure nitrogen is generally very expensive.
Warning! Ammonia is highly toxic! The presence of ammonia can be detected by its characteristic odour. Before
any inspection, the boiler or system components and installation area must be thoroughly ventilated.
Warning! Nitrogen has no smell. During any internal inspection of the boiler or system components, there is a
risk of suffocation if there are still pockets of nitrogen in the boiler or system components. The oxygen content
must therefore be checked before entering the boiler or system components if this method is used.
The technical data for the oxygen binders are given in the relevant manufacturer's information sheets and safety data
sheets.
Oxygen binders are supplied in closed containers. Unopened, liquid products can be stored for up to 1 or 2 years, depending
on manufacturer. Powder products can generally be kept for several years in unopened sacks that are stored in a dry place.
After opening, there is a risk that the products may react with oxygen in the air, thus reducing their effectiveness. For this
reason, liquid oxygen binders in particular can generally only be stored for a limited period after opening, and should be
used as quickly as possible. Products in powder form may become unusable after opening due to the effect of the humidity
in the air.
Chemicals should generally be stored at ambient temperature, at temperatures not higher than 40C and not below freezing
point.
In general, the recommendations provided by the relevant manufacturer should be followed for storage.
Page 6 of 7

G012
Version 1 (09/04)
Setting and Adjustment
You should use the measurement equipment provided by the chemicals suppliers to regularly check the surplus oxygen
binder and the pH.

repair:
Observation/fault:
Surplus oxygen binder too low when measured

(with wet conservation)
Cause
Repair
Supplementary dosage too low
Increase dosage of chemicals
Oxygen has leaked in
Check the leak tightness of all devices that seal the

boiler or system components off from its
surroundings
Observation/fault:
pH too low (with wet conservation)
Cause
Repair
Dosage too low
Add more alkalisation agents
Observation/fault:
By whom?
By whom?
Discoloration of Contents water (with wet conservation)
Cause
Repair
Oxygen leakage, corrosion
Check the leak tightness of all devices that seal the

boiler or system components off from its
surroundings
By whom?
Increase dosage of chemicals
Check circulation process
Page 7 of 7
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Main screen.................................................................................................................................................................. 3
6.2
Second-level screens ................................................................................................................................................... 6
6.3
Third-level screens ....................................................................................................................................................... 7
6.4
Buttons ....................................................................................................................................................................... 10
6.5
Screen keyboard ........................................................................................................................................................ 10
Setting and Adjustment ........................................................................................................................................... 11
Start-up ..................................................................................................................................................................... 11
Operation .................................................................................................................................................................. 11
9.1
Switching the boiler on ............................................................................................................................................... 11
9.2
Switching the boiler off ............................................................................................................................................... 12
9.3
Operating modes........................................................................................................................................................ 13
9.4
Switch control on/off ................................................................................................................................................... 14
9.5
Messages................................................................................................................................................................... 14
9.5.1
Current messages ...................................................................................................................................................... 14
9.5.2
Message archive ........................................................................................................................................................ 16
9.6
Measured values ........................................................................................................................................................ 17
9.6.1
Current measured values ........................................................................................................................................... 17
9.6.2
Counter ...................................................................................................................................................................... 18
9.6.3
Measured value curves .............................................................................................................................................. 19
9.7
Log in (Customer Service only) .................................................................................................................................. 20
9.8
System settings .......................................................................................................................................................... 21
9.8.1
Temperature limiter test ............................................................................................................................................. 23
9.8.2
Timer for compulsory inspection ................................................................................................................................ 23
9.8.3
Date and time............................................................................................................................................................. 25
9.8.4
Language ................................................................................................................................................................... 26
9.8.5
Version information and operating program update ................................................................................................... 26
10
Page 1 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
H026 Central Processing Unit CPU 313C
H022 operating and monitoring system TP 8 or H024 operating and monitoring system TP 10
The present Operating Instructions form the basis for the process description and the operation of the functions saved in the
controls. These Operating Instructions only describe the basic functions which are contained as a basis in every boiler
control.
All functions which are added at the customer's request to this basic equipment are explained in the enclosed individual
operating instructions. The Operating Instructions are compiled on an order-related basis for each individual system. The
chapter "Description of structure and function / description of process contains the necessary references to the individual
Loos Boiler Control LBC is solely intended for non-safety-related boiler controls.
The LBC is only intended for use on boilers with gas, oil or dual burners. Any use above and beyond this is not regarded as
use for the intended purpose.
The LBC may only be used by competent staff and on the boiler on which it was mounted and first commissioned according
to these Operating Instructions by personnel authorised by Loos International. Only if installation is properly carried out an
use in accordance with the regulations be ensured.
The LBC may only be used by trained staff.
The LBC consists of software and hardware components that have been matched to each other. You should only use Loos
International accessories and replacement parts for the LBC.
Danger! The control may not be changed, restructured or opened. If changes are made to the controls without
authorisation, the performance and operating safety of the system can no longer be guaranteed. The safety of
operating staff may also be at risk. Any use other than that described in these operating instructions will involved
dangers such as short-circuiting, electric shock or fire.
Use in accordance with regulations also includes reading these Operating Instructions and the operating instructions
referred to later and complying with all instructions contained therein, especially safety instructions.
The owner of the system, and not the manufacturer, is responsible for any personal injury or material damage occurring as a
result of use not in accordance with regulations.
Safety
Page 2 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
H026 Central Processing Unit CPU 313C
H022 operating and monitoring system TP 8 or H024 operating and monitoring system TP 10
You operate the LBC via a touch panel. Normally, you trigger an action by touching the desired area with your finger and
releasing it immediately afterwards. A black frame marks the activated area. If you keep touching the area on the panel and
move your finger out of it you will abort triggering of the action.
Some functions only operate as long as you press the panel (e.g. increasing/decreasing the pump speed in manual mode). If
this is the case it will be stated explicitly in the corresponding operating instructions.
Note: Never carry out several operations at the same time. You may possibly trigger unintentional actions in this
way. You should therefore only ever touch one point on the LBC touch panel at once.
The screens shown below are intended by way of example only. The precise appearance of your LBC touch panel will
depend on the scope of delivery you have ordered.
6.1
Main screen
Line 1
Line 2
Middle area
Lower line
Figure 1: Main screen single-flue boiler or
Main screen Twin-flue boiler
The main screen of the LBC LBC touch panel contains the following elements:
Status information (Line1):

Field 1:
Show a menu bar to call up the following functions: Switch control on/off, View messages, View
current measured values, View measured value curves, log on (only required for Loos Customer
Service), Change system settings (see Chapter 9.4 to 9.8)
Hide menu bar; appears if bar is shown
Back to screen at next highest level; appears at all levels underneath the main screen
Page 3 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Field 2:
Red: Priority 1 (and possibly Priority 2) messages waiting
Yellow: Priority 2 (but not Priority 1) messages waiting
Switch off hooter; appears with messages with acoustic signal
Field 3:
Boiler operating mode: Normal operation

Boiler operating mode: Primary (if boiler sequence control contained in the ordered scope of
delivery)
Boiler operating mode: Secondary (if boiler sequence control contained in the ordered scope of
delivery;
the number gives the position in the order of the sequence control )
Boiler operating mode: Heat maintenance
Boiler operating mode: Standby (if contained in the ordered scope of delivery)
Field 4:
Control operating mode: Local operation

Control operating mode: Remote control via central instrumentation and control (CIC; if contained in
the ordered scope of delivery)
Field 5:
Functions operating mode: All functions in automatic mode
Functions operating mode: At least one function in manual mode
Field 6:
green: Control is switched on
red: Control is switched off
Information on functions (line 2):

Field 1:
Field 2:
Single-flue boiler:
Current burner load (e.g. 70%, if measurement is contained in the ordered scope of
delivery)
Double-flue boiler:
Not allocated
Current burner load (e.g. 66%) for each burner in field 1, middle area
(if measurement is contained in the ordered scope of delivery)
Current volumetric flow at boiler return flow (e.g. 70 m/h, if measurement is contained in the ordered scope
Page 4 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
of delivery)
Field 3:
Single-flue boiler:
Current return flow temperature (e.g. 60C)
Double-flue boiler:
Current supply flow temperature (e.g. 74 C)
Field 4:
Current thermal capacity of the boiler (e.g. 2.4 MW if measurement is contained in the ordered scope of
delivery)
Field 5:
Single-flue boiler:
Double-flue boiler:
Current return flow temperature (e.g. 60C)
Field 6:
Current flue gas temperature (e.g. 110 C, if measurement is contained in the ordered scope of delivery)
Call of individual functions (middle area):

Field 1:
Burner dialogue:
Operating Instructions G366 to G370 Fuel Selection (if contained in the ordered scope of delivery)
Operating Instructions G360 to G365 Burner Control
Operating Instructions G334 to G337 Performance Regulation
Field 2:
Not allocated
Field 3:
Single-flue boiler: Return flow dialogue:

Operating Instructions G316 to G319 Return Flow Temperature Control
Operating Instructions G328 Lifting Pump (if contained in the ordered scope of delivery)
Operating Instructions G381 Return Flow Shut-off Valve (if contained in the ordered scope of delivery)
Operating Instructions G329 Boiler Circuit Pump (if contained in the ordered scope of delivery)
Double-flue boiler:
Supply flow dialogue:
Operating Instructions G382 Return Flow Shut-off Valve (if contained in the ordered scope of delivery)
Field 4:
Not allocated
Field 5:
Single-flue boiler:
Supply flow dialogue:
Operating instructions like field 3, double-flue boiler
Double-flue boiler:
Return flow dialogue:
Operating instructions like field 3, single-flue boiler
Field 6:
Flue gas dialogue (if functions are contained of the ordered scope of delivery):
Operating Instructions G346 Flue Gas Temperature Control
Operating Instructions G355 Flue Gas Heat Exchanger Inlet Temperature Control
Operating Instructions G327 Flue Gas Heat Exchanger Pump
Operating Instructions G376 Flue Gas Flap Control
Page 5 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Note: If several Operating Instructions are given for the individual (sub-) functions, this shows the number of
possible variants. In each LBC delivered, only the functions contained in the order are programmed. This means
that only one Operating Instruction per (sub-) function is ever possible.
Request for operating modes (lower line):
Field 1 / 2:
Run down boiler (see Chapter9.2)
Field 3 / 4:
Operating modes dialogue (see Chapter 9.3)
Field 5 / 6:
Start up boiler (see Chapter 9.1)
If particular functions are not part of the scope of delivery, the corresponding areas in the screen (main screen and second
level) are shown without a white frame and without special units in the diagram.
Figure 2: Example of main screen if certain functions are not part of the scope of delivery
(here: supply flow and flue gas functions)
6.2
Second-level screens
If you touch a function field in the middle part of the main screen, you will come to a second-level screen:
Line 1
Line 2
Middle area
Lower line
Figure 3: Main screen
(Example of) Second-level screen
Page 6 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
The second-level screens contain the following elements:

Field 1:
Back to main screen
Field 2 to 6:
Status information as in main screen
Function information (Line 2):

Field 1 to 6: Important Measured values or status information on individual components (depending on scope of delivery
ordered)
Request for sub-functions (middle area):
Field 1 to 6: Request for individual sub-functions (depending on scope of delivery ordered; generally, some or all fields are
grouped together into one larger field)
Navigation bar (lower line):
Field 1:
Straight to burner dialogue (in the example shown, this is the selected dialogue)
Field 2:
Not allocated
Field 3:
Straight to return flow dialogue
Field 4:
Not allocated
Field 5:
Straight to supply flow dialogue (if contained in the ordered scope of delivery)
Field 6:
Straight to flue gas dialogue (if contained in the ordered scope of delivery)
Note: A
in on one of the symbols in the navigation bar shows that the corresponding function or sub-function
is not in automatic mode.
6.3
Third-level screens
If you touch a field in the middle area of a second-level screen you will come to a third-level screen (operator and
parameterisation screen):
Page 7 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Line 1
Line 2
Middle area
Lower line
Figure 4: Example of a third-level screen
Special features:
Some functions have two successive screens in the second level. With these functions you have to select a subfunction twice before you come to an operator and parameterisation screen.
Figure 5: Example of successive screens in the second level
When you call an operator and parameterisation screen that requires the complete middle area of the touch panel, the
SET symbol will appear first. When you touch this symbol again you will come to the operator and parameterisation
screen in the third level:
Page 8 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Figure 6: Example of SET symbol
When you call a control as operator and parameterisation screen (that always requires the complete middle area of the
touch panel), the control symbol will appear first. When you touch this symbol again you come to the control screen
(operator and parameterisation) in the third level:
Figure 7: Example of a control call
Line 1
Line 2
Middle area
Lower line
Figure 8: Example of a control screen in the third level

Field 1:
Back to second-level screen
Page 9 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Field 2 to 6:
Status information as in main screen and second level

Field 1 to 6: Important measured values or status information on individual components (depending on scope of delivery
ordered)
Parameterisation (middle area):
Field 1 to 6: Select settings, display and enter values, operate (depending on scope of delivery ordered)
Navigation bar (lower line):
Field 1 to 6: As in second level
6.4
Buttons
If you touch a button, a dark grey frame will appear around the surface, e.g.:
Buttons that have not been selected are light green or light grey with white graphics, e.g.:
or
Selected buttons are dark green with white graphics, e.g.:
Example of a group of buttons, one of which has been selected:
Buttons that cannot be selected are dark grey with grey graphics, e.g.:
A button may be unavailable for selection, for example, if the action that it would trigger is currently illogical, if the action is
not contained in the ordered scope of delivery or if there is a system error.
6.5
Screen keyboard
Fields in which you can make entries are white with a green edge, e.g.
or white with a grey edge, e.g.
Fields in which values are displayed which have been calculated by the control system are grey without any edge, e.g.
If you touch the figure in an entry field, the screen keyboard appears.
The appearance of the screen keyboard depends on the LBC touch panel hardware. The following illustrations are therefore
only by way of example:
Page 10 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
or
Figure 9: Examples of numerical screen keyboards
Enter the required value. Save your entry with
Limits for entries are displayed; values outside these limits will not be accepted.
Setting and Adjustment
No particular setting and adjustment work is required during installation.

The system is adjusted the first time it is started up.
Start-up
The initial start-up may only be carried out by staff of Loos International or by persons who have been
expressly authorised by Loos International to carry out this work.
Operation
After switching on the main switch at the boiler control cabinet and starting up the LBC, the main screen will appear on the
LBC touch panel (see Figure 1). If there is a fault, the main screen is covered by a message window (see Figure 12).
If the boiler was commissioned and set by Loos Service or by people expressly authorised to do this by Loos International,
the main screen will contain the most important information for operating the boiler; other information can be called up from
there.
The pictures presented in the following are only exemplary (particularly in the brightened areas). The exact picture on your
LBC touch panel depends on the scope of delivery.
9.1
Switching the boiler on
The boiler can be switched on and off in the main screen. The following sequence must be observed:
For switching the control on, see paragraph 9.4
Operating mode check: The operating mode that has been set is displayed in field 3 and 4 of line 1 in the main screen.
For changing the displayed operating mode see paragraph 9.3
Check fuel selection via burner dialogue if necessary (field 1 in middle area of the main screen; see operating
Instructions on fuel selection, if contained in the ordered scope of delivery).
Switch all controls to automatic mode (see operating instructions of the individual controls).
Page 11 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Subsequently, the automatic mode (

grey (
When a control is in manual mode (noticeable by the

symbol is dark grey (
) is displayed in field 5 of line 1 and the boiler start-up symbol is light
).
symbol in the navigation bar), the boiler start-up
) and therefore not selectable.
Boiler start-up
Figure 10: Boiler start-up
The following applies to start-up of the cold boiler until the mean boiler supply flow temperature TVM is reached for the
first time:
With performance regulation in stages or mechanical compound performance regulation the system operates
in low load position.
With electronic compound regulation, the system operates with a fixed load default value (preset at 30%,
changeable by Loos Service, independent of the burner sequence for both burners of double-flue boiler
systems).
The system releases the performance regulation after the mean boiler supply flow temperature TVM has been reached.
The current boiler return and supply flow temperatures are displayed in field 3 and 5 of line 2 in the main screen.
9.2
Switching the boiler off
Figure 11: Running the boiler down
If you touch
All regulators will stay in the selected position.
The burner is switched off after 120 sec.
Switch the control off if necessary (see Section 9.4).
the burner will change in a controlled way to the low load position.
Page 12 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
9.3
Switch main switch on boiler control cabinet off if necessary.
Operating modes
Figure 12: Main screen
Operating modes

Field 1:
Field 3:
Field 5:
Boiler operating mode, e.g.

= Local control,
= Heat maintenance
= Remote control with central instrumentation and control (CIC)
= Control with Loos System Control
Field 2/4/6: not allocated
Actions:
Left block:
(Field 1 and field 2 of the middle area): See Operating Instructions G398 Heat Maintenance (if included in
the ordered scope of delivery)
Switchover to operation on site: No external intervention, all boiler control functions by LBC
Switchover to remote control by central control system (CIC): Functions specified in the order are triggered
by CIC, e.g. presetting of an external mean boiler supply flow temperature
Switching the control ON/OFF via the Loos System Control (independent of operation on site / remote
control with CIC, see Operating Instructions LSC G401): Functions specified in the order are triggered by
LSC, e.g. boiler sequence control
Page 13 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
9.4
Switch control on/off
Figure 13: Menu bar

The symbol in Field 6 of Line 1 changes from
and switching off the control blocks the outlets.
9.5
to
Switch control on/off

or vice versa. Switching on the control releases the LBC outlets,
Messages
If a fault occurs (priority 1 or 2 message), a message window appears on the LBC touch panel, no matter which screen is
currently being accessed. Priority 1 messages are also indicated acoustically with an intermittent tone or continuous tone
(fault will lead to failure of boiler).
Figure 14: Example of fault message
Actions:
Switch hooter off (only with Priority 1 messages)
Acknowledge message; message window disappears once all messages have been
acknowledged
A list of all fault alarms is given in the chapter "Measures in the event of unusual observations and operating faults".
9.5.1
Current messages
Call up the message memory to see the current messages that have already been acknowledged:
Page 14 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Figure 15: Menu bar
Call up message memory
Figure 16: Message memory - Example of current messages

Displays:
Grey: message in focus of viewer
Red: Priority 1 message,
indicated acoustically with intermittent or continuous tone (fault will lead to failure of boiler)
Yellow: Priority 2 message (no acoustic signal)
Green: Pre-warning
All messages contain the following elements: time, date; K = message arrived, Q = Message acknowledged (not for prewarnings), message code; message; any measured values at time of message.
Messages are displayed on the basis of time and date stamp, i.e. the most recent messages are at the top.
Actions:
Scroll down (touch once = bottom message in focus, touch again = bottom message top
message, display next messages)
Scroll up (touch once = top message in focus, touch again = top message bottom
Page 15 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Call up message archive
9.5.2
Message archive
Scroll bar
Figure 17: Message archive (can only be called up via current messages)
Displays:
Colours:
as for current messages
All messages contain the following elements: time, date; K = message arrived, Q = Message acknowledged (not for prewarnings), message code; message; any measured values at time of message.
Messages are displayed on the basis of time and date stamp, i.e. the most recent messages are at the top.
Actions:
Scroll down (touch once = bottom message in focus, touch again = bottom message top
Scroll up (touch once = top message in focus, touch again = top message bottom
Scroll bar:
For rapid scrolling in the message archive

Call up current messages
Page 16 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
9.6
Measured values
9.6.1
Current measured values
Figure 18: Menu bar
Call up current measured values
Figure 19: Examples of current measured values
Values whose measurement is part of the order scope of delivery are shown in dark lettering; values for which this is not the
case are shown in light lettering. If the measured values signal is faulty, ##### appears in the measured value display.
Actions:
Scroll down (at the end, the display starts again from the beginning)
Scroll up (at the end, the display starts again from the beginning)
Call up counter
Page 17 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
9.6.2
Counter
Figure 20: Operating hours counter and

example of quantity counter (if contained in scope of delivery)
(can only be called up via current measured values)
The operating hours counter for the boiler runs as soon as the control is switched on; it stops as soon as the control is
switched off (Betr.-h = operating hours).
The operating hours counter for the burners run as soon as the operating signal from the burner control device has
been received. It stops as soon as the burner switches off (Betr.-h = operating hours).
The burner start counter counts the burner requests to the burner control device.
When the dot changes from green
to grey
it shows that the boiler / burner is in operation.
The following meters can be ordered: Heat quantity, gas quantity and oil quantity meters.
Actions:
Reset counter (only with quantity counters; total cannot be reset)
Call up current measured values
Page 18 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
9.6.3
Measured value curves
Figure 21: Menu bar
Call up measured value curves
Figure 22: Example of list of measured value curves

Curves for which measurement of the corresponding values are part of the ordered scope of delivery are given in white
lettering on a green background; curves for which this is not the case are in light grey lettering on a dark grey background.
The following curves can be displayed, if the measurement of the corresponding values is part of the ordered scope of
delivery:
Supply / return flow temperature
Flue gas temperature
Burner load
Thermal capacity
Gas volume
Oil volume
Flue gas heat exchanger inlet temperature
The system files the measured values of supply flow, return flow and flue gas temperature continuously (over a limited
period of time). The other measured values are only saved as long as the corresponding curve is called.
Actions:
Page 19 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Figure 23: Example of selection of measured value curve
Example of measured value curve
Actions:
Back to earlier measured values
Forward to later measured values
Forward to current measured value
Reduce precision of presentation (enlarge time window)
Increase precision of presentation (reduce time window)
9.7
Log in (Customer Service only)
Figure 24: Menu bar
Call up log in
Page 20 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Figure 25: Log in

In order to access the special setting options intended solely for him, the Loos Customer Service Engineer must log in with
his user name and password.
Note: In normal operation, no log-in is required. If you accidentally hit the
call up the log-in screen, you can return to the main screen using the
button in the menu bar and thus

button on the top left!
Attention: The system only permits a limited number of log-in attempts. Several unsuccessful attempts to log in
can lead to faults in the boiler system.
9.8
System settings
Figure 26: Menu bar
Call up system settings
Page 21 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Figure 27: System settings
Actions:
Check pressure limiter (see Chapter 9.8.1)
Call up timer for compulsory inspection (see Chapter 9.8.2)
Calibrate touch panel (required if the panel does not react as expected when touched; follow
the instructions on the panel)
Clean touch panel (surface because insensitive to touch for a period of time indicted by a bar
diagram; for cleaning instructions, see Operating Instructions H022/H024)
Set date (see Chapter 9.8.2)
Set time (see Chapter 9.8.2)
Change language (see Chapter 9.8.3)
Call up version information (see 9.8.4)
Page 22 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
9.8.1
Temperature limiter test
Figure 28: Temperature limiter test (call via system settings)

You can check the operability of the temperature limiter by pressing the dark grey surface.
The burner operates as long as you press the surface. The temperature rises until the switching point of the temperature
limiter is reached. (The basic setting corresponds to the value defined by the technical data in the order confirmation.) The
boiler supply flow temperature in C is displayed in the dark grey surface.
The temperature limiter switches the burner off permanently and blocks it in the shut-down state.
Caution! Due to a possible malfunction of the temperature limiter, always pay attention that the boiler supply
flow temperature does not exceed the deactivation point of the temperature limiter. Release the grey surface
immediately if that is the case.
Testing the trip pressure of the pressure safeguard valve may only be carried out by Loos International
Service or by personnel authorised by Loos International to carry out this work.
9.8.2
Timer for compulsory inspection
The controls for shell hot water generators with a safeguard temperature > 110 C are fitted with a timer for compulsory
inspection. This prevents the boiler being operated for an unlimited period of time without the presence of operating staff.
The timer is linked to the function of the temperature limiter, i.e. the timer monitors whether the temperature limiter is
triggered within a waiting time TKZ. The possibilities are as follows:
The temperature limiter is triggered because of an actual fault during operation. This means that the operating staff will
need to be present on site.
The temperature limiter is tested deliberately by the operating staff according to Chapter 9.8.1.
The waiting time TKZ is preset at six months (4320 h). Depending on the national requirements, it can be set to max.
6 months (4320 h) and min. one day (24 h).
The remaining time, i.e. the time within which the temperature limiter must be triggered, is displayed on the LBC Touch
Panel. If the temperature limiter has been triggered, the remaining time is then set to the original start value TKZ.
Fault alarm 1:
If 75% of the waiting time TKZ has passed without the temperature limiter being triggered or tested, a fault alarm is given at
the LBC Touch Panel and registered in the message memory. The fault is indicated acoustically by an intermittent tone and
also notified by a floating contact. The boiler continues to operate without restrictions.
Fault alarm 2:
If the waiting time TKZ expires without the temperature limiter being triggered or tested, the burner is changed in a controlled
manner to the low-load position, irrespective of the current load requirement, and then switched off. A fault message is given
Page 23 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
at the LBC Touch Panel and registered in the message memory. The fault is indicated acoustically by a continuous tone and
also notified by a floating contact.
After it has been switched off, the burner must be released again by the operating staff at the LBC Touch Panel. Only
then can the burner be restarted.
Because the temperature limiter has not been triggered, the remaining time is set back to 25% of the set time TKZ. This
means that fault alarm 1 is repeated and the process is repeated until the temperature limiter has been triggered or a
test has been carried out.
If the temperature limiter is tested within the remaining time (or if it is triggered because of an actual fault) the remaining
time is set back to the start value TKZ.
Figure 29: Timer for compulsory inspection (called up via system settings)
Displays:
Field 1:
Remaining time for compulsory inspection in the range > 25% of TKZ
Remaining time for compulsory inspection in the range < 25% of TKZ, but > 0 (fault alarm 1)
Waiting time TKZ expired (Fault alarm 2)

Field 2 to 5:
Remaining time for compulsory inspection in hours, minutes and seconds
Actions:
Set waiting time TKZ
Release burner after end of waiting time TKZ
Page 24 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Figure 30: Call up waiting time
Setting the waiting time
Entry:
TKZ:
Waiting time in h
Note: With steam boilers which are not fitted with a timer for compulsory inspection (generally boilers with a
safeguard temperature < 110 C), the waiting time TKZ does not expire; it stays constant. The burner will
therefore also not be switched off.
9.8.3
Date and time
Figure 29: Set date and

(Call up via system settings)
Set time
Entries:
Date (Day . Month . Year)
Time (Hour : Minute : Second)

Actions:
Cancel
Page 25 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Save
The LBC has two independent clocks (incl. date indication). There is one clock in the LBC touch panel, and the other is in
the Central Processing Unit. As the program is running, these clocks are automatically synchronised at regular intervals, with
the clock in the Central Processing Unit setting the clock in the panel. The time and date can also be changed manually at
the panel, however. In this case, the settings must then be saved with
in the Central Processing Unit.
9.8.4
Language
Figure 30: Language (call up via system settings)

The top of the field displays the language currently selected for displays on the LBC touch panel. You can change the setting
by touching the required language in the lower area.
9.8.5
Version information and operating program update
Figure 31: Version information and operating program update (called up via system settings)
Displays:
Software version
Panel version
Page 26 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Actions:
Load MMC (MultiMediaCard) operator program update (see Operating Instructions H022, H023, H024)

repair:
Observation/Fault:
Code 1
Emergency switch triggered
Cause
Repair
Emergency switch has been operated
After rectifying any danger situation, the emergency

switch should be released again
Observation/Fault:
Code 5
By whom?
No control voltage / control fuse triggered
Cause
Repair
One or more control circuit fuses triggered
Check control circuit fuses and electr. system acc.

to current regulations
No power supply to control cabinet

Observation/Fault:
Code 21 Continuous tone

By whom?
Burner fault (single-flue boiler)

Burner fault left (double-flue boiler)
Burner fault right (double-flue boiler)
Cause
Repair

instructions
Observation/Fault:
Code 40
By whom?
LBC bus communication faulty
Cause
Repair
Bus connection from LSC system control to LBC

boiler control is faulty
Check bus connection, examine bus line for

damage
By whom?
Page 27 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/Fault:
Code 45 Intermittent tone
Waiting time TKZ 75% expired
Cause
Repair
75% of waiting time TKZ expired without

triggering/testing of limiter device
Carry out test on limiter device
Observation/Fault:
By whom?
Waiting time TKZ expired
Cause
Repair
Waiting time TKZ expired without triggering/testing

of limiter device
Carry out test on limiter device
Observation/Fault:
By whom?
Running time of flue gas flap
Cause
Repair
Flue gas flap not yet fully opened
Compare actual running time of flue gas flap motor

with the time entered in the LBC (set time in LBC
must be approx. 30 s higher)
Limit switch not triggered
Check setting of limit switch for opening in situ
Observation/Fault:
Code 57 Gas temperature transducer sensor breakdown
Cause
Repair
No measuring signal available
Check connection cables, transmitter feed and

transmitter, measurement signal must be in the
range 4...20mA
Observation/Fault:
By whom?
By whom?
Code 63 Burner load position: No signal
Cause
Repair

range 4...20mA
By whom?
Page 28 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/Fault:
Code 69 Burner gas pressure transducer sensor breakdown
Cause
Repair

range 4...20mA
Observation/Fault:
Code 71
Gas volume measurement: No signal
Cause
Repair

range 4...20mA
Observation/Fault:
Code 73
Repair

range 4...20mA
Code 75
By whom?
Waste gas temperature measurement: no signal
Cause
Repair
No measurement signal available
Check connection cables, measuring transmitter

feed and measuring transmitter; measurement
signal must be in the range 4..20mA
Observation/fault:
By whom?
Oil volume measurement: No signal
Cause
Observation/Fault:
By whom?
By whom?
Code 102 - Continuous tone Temperature limiter for hot water generator
Cause
Repair

adjusted or faulty
Mean forward flow temperature too close to trigger

temperature of temperature limiter
Set mean forward boiler flow temperature TVM

lower
By whom?
Page 29 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/Fault:
Boiler water shortage
Cause
Repair
Strong pressure drop in hot water network
Check pressure maintenance
Leakage in hot water network
Eliminate leakage
Observation/Fault:

Boiler safety chain triggered (boiler fault)
Cause
Repair

limiters


Observation/fault:
By whom?
Code 108 - Continuous tone Temperature blow min. return flow tempreature
Cause
Repair
Reduce removal of warmth from network.
Too many consumers in network
Disconnect consumers
Observation/Fault:
By whom?
Code 109
By whom?
Boiler manostat tube limit switch
Cause
Repair
Valve at manostat tube shut
Open valve at manostat tube
By whom?
Page 30 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/Fault:
Code 111
Boiler circuit pump fault
Cause
Repair
By whom?
Motor protection switch has responded
Check boiler circuit pump
Check motor protection switch
Observation / Fault:
Fault: lifting pump
Cause
Repair
By whom?
Motor protection switch triggered
Check lifting pump
Fault in frequency converter
Observation/fault:
Check frequency converter
Fault in FHE pump
Cause
Repair
By whom?
Motor protectoin switch triggered
Check FHE pump
Observation/fault:
Heat maintenance pump fault
Cause
Repair
Check heat maintnance pump
By whom?
Page 31 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/Fault:
Fire protection thermostat
Cause
Repair
Fire protection thermostat has reacted (via firing)
Check firing and unlock fire protection thermostat
Observation/fault:
By whom?
Code 125 Continuous tone Max. pressure limiter 1

Code 126 Continuous tone Max. pressure limiter 2
Cause
Repair
Pressure limiter set incorrectly, badly adjusted or

faulty
Observation/fault:
By whom?
Code 127 Continuous tone Min. pressure limiter 1

Code 128 Continuous tone Min. pressure limiter 2
Cause
Repair

faulty
Observation/Fault:
By whom?
Burner preset waiting time
Cause
Repair
The fuel selection switch of dual burners is in OFF

position
Preselect fuel with fuel selection switch
Switch on burner switch
Burner fault
Remove burner fault and deblock with deblocking

device at burner or boiler control cabinet
Boiler fault
Remove boiler fault and deblock with deblocking

device at boiler control cabinet
Flue gas valve not opened
Check flue gas flap function
Air supply flap not opened
Check air supply flap function
By whom?
Page 32 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Cause
Repair
Pressure transducer sensor breakdown (code 61)
See code 61
Supply flow temperature transducer sensor

breakdown (code 161)
See code 161
Hot water boilers: Minimum flow not reached
Check minimum flow
Observation/Fault:
Cause
Repair
Oil leakage at oil lines
Seal oil lines
Observation/Fault:
By whom?
Burner oil leakage

By whom?
Min. boiler flow
Cause
Repair
Wrong parameter setting
Set parameters correctly
Water return flow volume too low
Increase water volume
Observation/Fault:
Code 138 intermittent tone
By whom?
Return flow shut-off valve operating time error
Cause
Repair
Shut-off valve is not fully open yet
Compare actual operating time of the flue gas flap

motor with the time entered in the LBC (setting time
in LBC must be approx. 30 sec. longer)
Observation/fault:
By whom?
Code 160 Sensor breakdown, temperature sensor, boiler return flow
Cause
Repair

range 4...20mA
By whom?
Page 33 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/fault:
Code 161 Sensor breakdown, temperature sensor, boiler forward flow
Cause
Repair

range 4...20mA
Observation/Fault:
Code 166 Sensor breakdown of return flow temperature maintenance valve

position indicator
Cause
Repair

range 4...20mA
Observation/Fault:
Repair

range 4...20mA
By whom?
Code 168 Boiler return flow measurement: No signal
Cause
Repair

range 4...20mA
Observation/Fault:
By whom?
Code 167 Thermal capacity measurement: No signal
Cause
Observation/Fault:
By whom?
By whom?
Code 176 Return flow temperature before admixture: No signal
Cause
Repair

range 4...20mA
By whom?
Page 34 of 35
Loos-Boiler-Control
LBC
G301
Version 2 (03/08)
Observation/Fault:
Code 177 No FHE inlet temperature measurement signal
Cause
Repair

range 4...20mA
Observation/Fault:
Code 178 Ambient temperature: No signal
Cause
Repair

range 4...20mA
Observation/Fault:
By whom?
By whom?
Code 180 Boiler supply flow temperature external default: No signal
Cause
Repair

range 4...20mA
By whom?
Page 35 of 35
Return flow temperature control

with speed controlled lifting pump
G316
Version 1 (11/07)
Contents
1
Safety .......................................................................................................................................................................... 1
6.1
General ........................................................................................................................................................................ 2
6.2
Return flow temperature control ................................................................................................................................... 2
6.2.1
Automatic mode ........................................................................................................................................................... 2
6.2.2
Manual mode ............................................................................................................................................................... 2
6.3
Minimum boiler return flow temperature monitoring ..................................................................................................... 3
6.3.1
Recommissioning ......................................................................................................................................................... 3
6.3.2
Minimum water flow rate monitoring............................................................................................................................. 3
Operation .................................................................................................................................................................... 3
7.1
Return flow temperature control ................................................................................................................................... 3
7.2
Minimum boiler return flow temperature monitoring ..................................................................................................... 5
G301 Loos Boiler Control (LBC) for shell hot water generators
Safety
Page 1 of 8

G316
Version 1 (11/07)
6.1
General
The lifting pump delivers water from the boiler supply flow to the boiler return flow.
Note: The frequency converter of the lifting pump must be set at a suitable minimum speed to ensure the
necessary minimum discharge capacity of the lifting pump.
The temperature transducer measures the boiler return flow temperature before entry into the boiler and transforms it into an
electric standard signal (4 to 20 mA). The Loos Boiler Control LBC (see Operating Instructions G301) processes this signal
and evaluates it according to the selected control mode.
As long as the automatic return flow shut-off valve is not completely open, the lifting pump is triggered according to the
criteria for switching on and off described in the Operating Instructions G328. The pump operates at 100% speed
independent of the temperature. The system releases the control as soon as the return flow shut-off valve has been open for
3 minutes (feedback from return flow shut-off valve limit switch).
With automatic shut-down of the boiler or switchover to the heat maintenance operating mode, the lifting pump runs for a
run-on time TNL before it switches off. TNL is preset at 180 sec.
6.2
The lifting pump is triggered via two adjustable switching points and via a setpoint.
The return flow temperature controller in the LBC controls the lifting pump with the setpoint TRM (mean boiler return flow
temperature). TRM results from the mean boiler supply flow temperature TVM and the temperature difference DTRM
between boiler supply flow and boiler return flow, i.e. TRM = TVM - DTRM. The parameter DTRM can be adjusted on the
LBC touch panel within certain limits.
The activation point of the lifting pump is TPE = TRM.
The switch-off point of the lifting pump is TPA = TRM + DTPA. The parameter DTPA can be adjusted on the LBC touch
panel within certain limits.
Automatic or manual mode can be selected.
6.2.1
Automatic mode
In order to avoid operating faults and damage to the boiler zu vermeiden, in the return flow temperature controller, the
ranges for setting the mean boiler return flow temperature are limited ex factory. These limits may only be changed within
the released ranges.
6.2.2
Manual mode
Manual operation is always possible if no fault has appeared and no minimum pressure limiter has responded. The lifting
pump speed can be increased or reduced to the minimum speed of the lifting pump. The return flow temperature control is
not active in manual mode.
Page 2 of 8

G316
Version 1 (11/07)
6.3
Minimum boiler return flow temperature monitoring
When the temperature falls below the minimum boiler return temperature TRL = TRM DTRL, first of all a warning appears
in the return flow dialogue on the LBC touch panel. When the temperature falls below TRL for more than 180 seconds the
system switches the firing off.
Fault message:
When the temperature falls below the minimum boiler return flow temperature TRL for more than 180 seconds, a fault
message appears on the LBC touch panel and is registered in the event memory. The fault is indicated acoustically by a
permanent signal.
The fault message disappears when the boiler return flow temperature exceeds TRL again or when monitoring is
deactivated.
Return flow temperature monitoring can be deactivated in the return flow dialogue on the LBC touch panel. Monitoring is
activated automatically when the boiler return flow temperature exceeds TRL again.
6.3.1
Recommissioning
With automatic recommissioning or start-up from the cold state, monitoring of the minimum boiler return flow
temperature is deactivated automatically until the system reaches TRL.
With manual recommissioning, return flow temperature monitoring in the return flow dialogue must be deactivated. This
ensures that the burner does not switch off when the temperature falls below the minimum boiler return flow
temperature during start-up. The system automatically reactivates return flow temperature monitoring when TRL is
reached.
6.3.2
Minimum water flow rate monitoring
When the minimum boiler water flow rate preset at the flow monitor is reached, the lifting pump is automatically brought up
to 100% speed for 5 minutes independent of the current temperature. After this time has elapsed the system releases the
pump control again.
If the flow rate still falls below the minimum boiler water flow rate preset at the flow monitor, the system switches the burner
off after a preset operating delay.
Fault message:
When the flow rate falls below the minimum boiler flow rate for more than the preset operating delay, a fault message
appears on the LBC touch panel and is registered in the event memory. The fault is indicated acoustically by a permanent
signal. The fault message disappears when the boiler return flow volume has increased so far that the flow monitor releases
again.
Operation
The basic operating principles for the LBC touch panel are described in the operating instructions G301, chapter
Description of Structure and Functions / Description of Process.
7.1
The following figures show the return flow temperature control selection:
Page 3 of 8

G316
Version 1 (11/07)
Figure 1: Return flow dialogue selection
Return flow temperature control selection
Figure 2: Return flow temperature control selection

Field 1:
Not allocated
Field 2:
Current lifting pump speed, e.g. 100%
Field 3 / 4:
Not allocated
Field 5:
Current return flow temperature, e.g. 60C
Field 6:
Mean return flow temperature, setpoint TRM, e.g. 55C
Inputs:
DTRM:
Temperature difference in K between supply flow temperature TVM and return flow temperature
TRM = TVM - DTRM
DTPA:
Distance in K between mean return flow temperature and lifting pump switch-off point TPA = TRM + DTPA
Actions:
Manual increase of the lifting pump speed (as long as the field is being touched)
Activates automatic operating mode
Page 4 of 8

G316
Version 1 (11/07)
Manual reduction of the lifting pump speed down to the minimum speed (as long as the field
is being touched)
Activates manual operating mode
7.2
Minimum boiler return flow temperature monitoring
When the temperature falls below the minimum boiler return flow temperature a red warning appears in the return flow
dialogue:
Figure 3: Return flow dialogue warning

The return flow temperature monitoring can be selected and deactivated (independent of the warning).
Return flow temperature monitoring selection
Page 5 of 8

G316
Version 1 (11/07)
Figure 5: Return flow dialogue warning

Field 1:
Field 2:
Mean return flow temperature, setpoint TRM, e.g. 55C
Field 3:
Not allocated
Field 4:
Return flow shut-off valve position:

=
Final position return flow shut-off valve OPEN reached
Return flow shut-off valve opens, no final position reached
(No display) =
Return flow shut-off valve not triggered, no final position reached
Return flow shut-off valve closes, no final position reached
Final position return flow shut-off valve CLOSED reached
Field 5:
Not allocated
Field 6:
Current lifting pump speed, e.g. 100%
Actions:
Deactivates return flow temperature monitoring
Page 6 of 8

G316
Version 1 (11/07)
repair:
Observation/fault:
Code 108 - Continuous tone Temperature blow min. return flow tempreature
Cause
Repair
Switching points set wrongly
Observation/Fault:
Code 135 Flow rate below boiler minimum flow rate
Cause
Repair
Boiler return flow water volume too low
Increase boiler return flow water volume
Observation/fault:
By whom?
Code 160 Sensor breakdown, temperature sensor, boiler return flow
Cause
Repair

range 4...20mA
Observation/fault:
By whom?
By whom?
Code 161 Sensor breakdown, temperature sensor, boiler forward flow
Cause
Repair

range 4...20mA
By whom?
Page 7 of 8

G316
Version 1 (11/07)
Observation/Fault:
Code 168 Boiler return flow measurement: No signal
Cause
Repair

range 4...20mA
Observation/fault:
Mean boiler return flow temperature is not reached
Cause
Repair

menu
Observation/fault:
By whom?
By whom?
Constant fluctuation of return flow temperature control
Cause
Repair
Temperature transducer faulty
Replace temperature transducer
By whom?
Page 8 of 8
Operating Instruction
Lifting pump
G328
Version 1 (11/07)
Contents
1
Safety .......................................................................................................................................................................... 1
6.1
General ........................................................................................................................................................................ 2
6.2
Automatic operation ..................................................................................................................................................... 2
6.2.1
Normal mode ............................................................................................................................................................... 2
6.2.2
Operating mode warm-keeping.................................................................................................................................... 2
6.3
Manual operation ......................................................................................................................................................... 2
6.4
Fault alarms ................................................................................................................................................................. 2
Operation.................................................................................................................................................................... 2
Safety
Page 1 of 4
Lifting pump
G328
Version 1 (11/07)
6.1
General
The lifting pump conveys the water from the boiler supply flow to the boiler return flow. If the lifting pump has stopped or if
there is a fault, the burner is switched off.
If the network pressure falls to the point where a minimum pressure limiter is triggered, the lifting pump is switched off
automatically.
With automatic shut-down of the boiler or switchover to the heat maintenance operating mode, the lifting pump runs for a
run-on time TNL before it switches off. TNL is preset at 180 sec.
If the lifting pump is provided by the client and the control is within the scope of deliver of Loos International, please note
Technical Information TI033 as regards signal exchange.
6.2
Automatic operation
In automatic operation, the lifting pump is controlled via the preselected operating mode if the following preconditions are
met:
There is no fault (motor protection, fault with frequency converter in speed-regulated lifting pumps).
No minimum pressure limiter has been triggered.
6.2.1
Normal mode
6.2.2
Operating mode warm-keeping
If heat maintenance mode is included in the scope of delivery, the lifting pump is controlled in this mode via the switching on
and off criteria for heat maintenance (see Operating Instructions G398).
6.3
Manual operation
Manual operation is always possible if there is not fault and no minimum pressure limiter has been triggered.
6.4
Fault alarms
When the motor protection switch is triggered or if there is a fault in the frequency converter (in the case of speed-regulating
lifting pumps), a fault alarm is given in the LBC Touch Panel and registered in the alarm memory. The fault is indicated
audibly by a continuous tone.
Operation
The following illustrations show the lifting pump control selection:
Page 2 of 4
Lifting pump
G328
Version 1 (11/07)
Figure 1: Selecting the return flow dialogue
Selecting the lifting pump control
Figure 2: Lifting pump control

Field 1:
Field 2:
Average return flow temperature, setpoint value TRM, e.g. 55C
Field 3:
Not allocated
Field 4:
Position of return flow shutoff valve:

=
Limit position return flow shutoff valve OPEN reached
Return flow shutoff valve OPENing, limit position not reached
(no display) =
Return flow shutoff valve not triggered, limit position not reached
Return flow shutoff valve SHUTting, limit position not reached
Limit position return flow shutoff valve SHUT reached
Field 5:
Not allocated
Field 6:
Current speed of lifting pump (e.g. 100%), if a speed-regulated lifting pump is included in the scope of
delivered ordered
Page 3 of 4
Lifting pump
G328
Version 1 (11/07)
Actions:
Activate automatic operating mode: the lifting pump is controlled via the preselected operating
mode (see Operating Instructions G316 or G319 and G398)
Activate manual operating mode: the lifting pump operates (at maximum speed) as long as
there is no fault and no minimum pressure limiter has been triggered
Switch off lifting pump
repair:
Observation/fault:
Lifting pump fault
Cause
Repair
Check lifting pump
By whom?
Frequency converter is faulty
Observation/fault:
Check frequency converter
Lifting pump not working
Cause
Repair
Control not switched on
Switch on control
Minimum pressure limiter (Code 127/128) triggered
Check network pressure
Boiler not in normal operating mode
Set normal operating mode
Lifting pump faulty
Check lifting pump
Lifting pump provided by customer
Check signal exchange and customer control of

lifting pump
By whom?
Page 4 of 4
Performance regulation infinitely variable

load request via permanent signal or
load request via 3-step signal with positioner
Double-flue boiler with one-flue operation
G339
Version 1 (08/08)
Contents
1
Safety .......................................................................................................................................................................... 1
6.1
General ........................................................................................................................................................................ 2
6.2
Performance regulation ................................................................................................................................................ 2
6.2.1
Automatic mode ........................................................................................................................................................... 2
6.2.2
Manual mode ............................................................................................................................................................... 3
6.3
Setpoint switchover ...................................................................................................................................................... 3
6.4
Ambient temperature compensation............................................................................................................................. 4
Operation .................................................................................................................................................................... 4
7.1
Performance regulation ................................................................................................................................................ 5
7.2
Ambient temperature compensation............................................................................................................................. 6
7.3
Timer ............................................................................................................................................................................ 7
Safety
Page 1 of 11

G339
Version 1 (08/08)
6.1
General
Basically a burner/boiler system is a slow-reacting system. All control devices and actuators that are linked with this system
are tuned to this behaviour. Under no circumstances should any attempt be made to adjust the temperature at the consumer
units via measures at the boiler. Before the consumer units, suitable fine temperature-adjustment devices must be provided.
Attention: Danger of serious damage to the boiler. With infinitely variable burner systems, the individual
actuators (e.g. air flap adjuster motor) should not go below particular minimum running times (switchover time
from low load to high load within 30 seconds) during burner operation in order reliably to avoid heat transfer
faults in the boiler. If heat transfer faults occur frequently, the boiler may be very seriously damaged.
The boiler supply flow temperature serves as the parameter for the performance regulation of the burner. The temperature
transducer measures the boiler supply flow temperature and converts it into an electrical standard signal (4 20 mA). This
signal is processed in the Loos Boiler Control LBC (see Operating Instructions G301) and evaluated, depending on the type
of regulation selected. The burner is controlled via adjustable switching points or setpoints.
If ambient temperature compensation is included in the scope of delivery of a boiler, the boiler supply flow temperature can
be adapted according to the ambient temperature.
6.2
Performance regulation
The burner control device and thus the burner are controlled via an adjustable setpoint (mean boiler supply flow temperature
TVM) at the performance regulator in the LBC.
TVM has been preset at 90% of the temperature limiter response temperature by the factory.
The response temperature of the temperature limiter is set directly at the limiter by Loos Service.
There are two possible load request variants:
Load request via permanent signal: The load request is transferred to the compound controller at the burner as
standard electrical signal (4 20mA).
Load request via 3-step signal with positioner: The load request is transferred as 3-step signal (open-stop-close) to
the compound controller at the burner via the positioner located upstream.
6.2.1
Automatic mode
The setting range for the mean boiler supply flow temperature has been limited by the factory to avoid operating faults and
damage to the boiler. You can only adjust values within the specified range.
The setting of TVM leads to the following switching points (presettings refer to 100% of the temperature limiter response
temperature):
Page 2 of 11

G339
Version 1 (08/08)
Burner OFF:
Preset at 95 %
Burner ON:
Preset at 85 %
The switching points for burner OFF/ON are linked to the mean boiler supply flow temperature TVM and are displaced
parallel with TVM. The performance regulator tries to adjust the set mean boiler supply flow temperature in an infinitely
variable way within these two switching points.
The burner switch must be in ON position to enable the start of the burner (see burner control Burner Control Operating
Instructions G360 to G363). If you set the performance regulation at automatic operation after start-up from the cold state,
the system operates with a fixed load default Y0 (preset at 30% for both burners, adjustable by Loos Service) until TVM is
reached for the first time. When TVM is reached the system releases performance regulation.
When the burner starts operating, an automatic timer limits the burner load to low load (preset to a light load time T_LL of
180 seconds, adjustable by Loos-Service). With a low heat requirement, this prevents uncontrolled switching on and off of
the burner. This automatic mechanism prevents unnecessary pre-ventilation losses and protects the boiler and firing
components. After the light load time T_LL has ended, the performance regulation is released.
6.2.2
Manual mode
The burner load position can be opened, closed or stopped in a position in between with the speed of 1% of the load change
per second. Performance control is not active in manual mode.
Furthermore, it is possible to preselect the load directly. The control activates this pre-selected value and keeps it for so long
until the switching off point of the burner TBA is reached or until the presetting is manually changed.
If the switching off point of the burner TBA is exceeded in manual mode, the burner switches off independently of the current
load position.
Note: If, with gas burners, the burner is switched off with a burner load > low load, the resultant back-pressure
can cause the safety shutoff valve to close which blocks the gas supply.
6.3
Setpoint switchover
For the mean boiler supply flow temperature TVM it is possible to switch between two set points (TVM1 und TVM2). The
following points should be noted:
TVM1 is the basic setting for normal operation.
Switchover from TVM1 to TVM2 and vice versa takes place via a programmed ramp (temperature change 1 C per 60
seconds). This prevents the burner from switching off before the low load setting is reached (so that the safety shutoff
valve does not close accidentally with gas operation).
The programme contains a timer which can be activated for operation on site. As an alternative to manual preselection of
TVM1 or TVM2, in the timer you can also program eight intervals (with different allocations of weekdays) with preselected
TVM2.
For boiler systems that are equipped with the preconditions for operation via a central instrumentation and control (CIC)
(potential-free contacts, signal separator, or connection to Profibus DP), the following possibilities exist for operation via the
CIC:
Switching over from TVM1 to TVM2 and back as binary contact or via Profibus DP; or alternatively:
Laying down an external mean boiler supply flow temperature (TVMX) as analogue signal (4 20 mA) or via Profibus
DP.
Page 3 of 11

G339
Version 1 (08/08)
Important for boilers without automatic start-up and shut-down control!

If any components are triggered by the central control system CCS (operating mode remote control) and
there is on-site intervention during this time or
a boiler or burner fault occurs

the system automatically switches over to on-site operation operating mode. Then the settings for on-site
operation are applicable. For switching back to CCS component triggering select the remote control operating
mode on the LBC touch panel (see Operating Instructions G301).
6.4
Ambient temperature compensation
If included in the scope of delivery, an ambient temperature sensor (see Operating Instructions I016) measures the ambient
temperature TA and transforms it into a standard electrical signal (4 to 20 mA). The Loos Boiler Control (LBC) processes this
signal (see Operating Instructions G301). The system adapts the preset boiler supply flow temperature (TVM1 or TVM2) via
the following context according to the ambient temperature:
TVM = TVM1 + K x (TEM - TA) or TVM = TVM2 + K x (TEM - TA)
TEM is the mean ambient temperature averaged over the year (preset at 10C, ask your local meteorological service). The
temperature adaptation coefficient K is preset at 0.2 (recommended values from 0.2 to 0.6).
Figure 1: Mean boiler supply flow temperature TVM according to the ambient temperature TA (in C)
Operation
Page 4 of 11

G339
Version 1 (08/08)
7.1
The following figures show the performance regulation selection:
Figure 2: Performance regulation selection

Field 1:
Current load burner 1, e.g. 60 %, if load setting indication is included in the order
Field 2:
Current load preset by the control unit, e.g. 10%
Field 3:
Current load burner 2, e.g. 0 %, if load setting indication is included in the order
Field 4:
Current ambient temperature, e.g. 10 C, if ambient temperature compensation is included in the order
Field 5:
Field 6:
Mean supply flow temperature setpoint, e.g. 90C (in case of CCS operation with presetting of an external
mean supply flow temperature this value is preset by the CCS).
Inputs:
TVM1:
st
Mean supply flow temperature in C (1 setpoint), basic setting for normal operation
TVM2:
Mean supply flow temperature in C (2nd setpoint)
Left field:
Manual load default, e.g. 10% The control unit activates this pre-selected value and keeps it until the
switching off point of the burner is reached or until the presetting is manually changed.
Actions:
As long as you touch the field: Manual opening of the burner servo motor with the speed of
1% load change per second
Activation of automatic operating mode
Page 5 of 11

G339
Version 1 (08/08)
As long as you touch the field: Manual closing of the burner servo motor with the speed of 1%
load change per second
Activation of manual operating mode
Activation of the ambient temperature compensation
Deactivation of the ambient temperature compensation
Call of the ambient temperature compensation settings
Activation of TVM1 for mean supply flow temperature in on-site operation
Activation of TVM2 for mean supply flow temperature in on-site operation
Activation of TVM1 / TVM2 preselection via timer
Call of timer programming
7.2
Ambient temperature compensation
Select the ambient temperature compensation settings on the performance regulation screen:
Figure 3: Selection of ambient temperature settings
Ambient temperature compensation settings
Inputs:
TEM:
Mean ambient temperature averaged over the year
K:
Temperature adaptation coefficient: TVM = TVM1 + K x (TEM - TA) or TVM = TVM2 + K x (TEM - TA)
Page 6 of 11

G339
Version 1 (08/08)
7.3
Timer
Select the timer programming on the performance regulation screen:
Figure 4: Timer programming selection
Timer programming
Note: When the TVM1 / TVM2 preselection has been activated by the timer without any switching time being
programmed, TVM1 is always preselected as mean supply flow temperature.
Field 1:
Field 2:
Field 3:
= Timer applies to TVM2 preselection (not changeable, TVM1 is preselected any time TVM2 has not
been preselected, also see field 2)
= Current time is within programmed interval = TVM2 currently selected
Not allocated
Field 4 to 6: Present date and present time
Display:
Programmed intervals (8 intervals, green = enter data, light grey = no data entered,
white = selected interval for data entry)
Actions:
Select previous interval
Select next interval
Note: When you modify data or enter new data for an interval (start, end, allocated weekdays), the display
flashes until you accept the data for the interval or abort the entry (see below).
Page 7 of 11

G339
Version 1 (08/08)
Inputs:
Left field:
Start of the time interval for TVM2 preselection
Right field:
End of the time interval for TVM2 preselection
Actions:
to
Weekday selection (Monday to Sunday, multiple selection possible)
Abort entry
Accept data for interval
Delete all intervals
Note:
If
time
exceeds
the
change
of
day,
two
intervals
must
be
programmed:
One interval ends at 23:59:59 on the first day and the other interval starts at 00:00:00 on the second day.
The number 24 is not accepted as hour indication.
Setting example:
The setting displayed in figure 5 switches over to TVM2 preselection from Monday to Thursday at 15:05:00 and back to
TVM1 preselection at 17:05:00. Besides this preselected time for TVM2, three further intervals (preselected times for TVM2)
have been programmed.
repair:
Observation/Fault:
Code 63
Code 64
Burner load on left: no signal (DFB)

Burner load on right: no signal (DFB)
Cause
Repair
No measurement signal
Check connection cables, measuring transmitter

feed, measuring transmitter and position sensor;
signal from measuring transmitter must be in the
range 4..20mA
By whom?
Page 8 of 11

G339
Version 1 (08/08)
Observation/fault:
Code 102 - Continuous tone Temperature limiter for hot water generator
Cause
Repair

adjusted or faulty
Mean forward flow temperature too close to trigger

temperature of temperature limiter
Set mean forward boiler flow temperature TVM

lower
Observation/fault:
By whom?
Code 125 Continuous tone Max. pressure limiter 1 for hot water generator
Code 126 Continuous tone Max. pressure limiter 2 for hot water generator
Code 127 Continuous tone Min. pressure limiter 1 for hot water generator
Code 128 Continuous tone Min. pressure limiter 2 for hot water generator
Cause
Repair

faulty
Mean supply flow temperature TVM too close to

trigger pressure of pressure limiter
Adjust mean supply flow temperature TVM
Observation/fault:
generators
Code 161 Sensor breakdown, supply flow temperature transducer for hot water
Cause
Repair

range 4...20mA
Observation/fault:
By whom?
By whom?
Code 180 External mean boiler supply flow temperature - no signal
Cause
Repair
Check connection cables and isolation amplifier, the

measurement signal of the isolation amplifier must
be in the range 4...20mA
By whom?
Signal at site faulty
Page 9 of 11

G339
Version 1 (08/08)
Observation/fault:
Burner switches on an off frequently
Cause
Repair
Temperature difference between Burner On and

Burner Off not enough
Increase temperature difference
Observation/Fault:
Burner only operates at low load
Cause
Repair
Performance regulation only released for low load
Release performance regulation in the Control

menu
Observation/Fault:
By whom?
Burner only operates in low load
Cause
Repair
Performance regulation only released for low load
Release performance regulation in the control menu
TVM not yet reached during start-up
Wait until TVM is reached
Observation/fault:
By whom?
By whom?
Mean boiler supply flow temperature TVM is not reached
Cause
Repair

menu
By whom?
Increase return flow temperature
Observation/fault:
Continuous fluctuation of performance regulation
Cause
Repair
By whom?
Page 10 of 11

G339
Version 1 (08/08)
Cause
Repair
Temperature transmitter faulty
Replace temperature transmitter
Observation/Fault:
By whom?
Safety shutoff valve falls in gas operation
Cause
Repair
Burner switches off in a load stage > low load
Check adjustment parameters and switching points
By whom?
Page 11 of 11
Burner control
Double-flue boiler with single-flue operation
for Shell Boilers
G361
Version 1 (10/08)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
General ........................................................................................................................................................................ 2
6.2
Burner sequence control and fault switchover.............................................................................................................. 2
6.3
Burner start .................................................................................................................................................................. 2
6.4
Automatic light load and subsequent control operation ................................................................................................ 3
6.5
Burner cut-out in normal operation ............................................................................................................................... 4
6.6
Controlled shut-down ................................................................................................................................................... 4
6.7
Faults ........................................................................................................................................................................... 4
6.7.1
Boiler faults .................................................................................................................................................................. 4
6.7.2
Burner fault................................................................................................................................................................... 5
Operation .................................................................................................................................................................... 5
7.1
Burner sequence control .............................................................................................................................................. 5
7.2
Firing switch ................................................................................................................................................................. 6
7.3
Burner control............................................................................................................................................................... 8
G300 Loos Boiler Control (LBC)
G338 Performance Regulation of Double-Flue Boilers with One-Flue Operation, Shell Steam Generators
G339 Performance Regulation of Double-Flue Boilers with One-Flue Operation, Shell Hot Water Generators
G338 Performance Regulation of Double-Flue Boilers with One-Flue Operation, Shell Steam Generators
Page 1 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
G339 Performance Regulation of Double-Flue Boilers with One-Flue Operation, Shell Hot Water Generators
Safety
6
6.1

General
The following actions are possible in the burner dialogue of the LBC touch panel:
Selection of a burner sequence control
Switching the complete firing system ON and OFF or automatically controlled shut-down
Switching the individual burners ON and OFF or automatically controlled shut-down
6.2
Burner sequence control and fault switchover
The following options are available in the burner sequence control image of the LBC touch panel:
Burner 1 as primary burner, burner 2 as secondary burner
Burner 1 and burner 2 in parallel operation
Start, control operation, switching-off and shut-down of the burners with the various settings is described in chapter 6.3 to
6.6.
If one of the burners has been selected as primary burner and the other one as secondary burner and a burner fault occurs
at the primary burner, the secondary burner automatically becomes the primary burner. The faulty primary burner becomes
the secondary burner after fault clearance and deblocking at the burner control of the secondary burner. The system
automatically changes the pre-selected burner sequence on the LBC touch panel. Thus, fault switchover is a compulsory
changeover of the burner sequence.
If both burners are operated in parallel, the respective other burner remains in operation in case of a burner operating fault.
6.3
Burner start
Switch ON the firing in the firing switch image of the LBC touch panel.
Switch ON at least one or (normally) both burners in the burner control images of the LBC touch panel.
The following requirements must be met to facilitate start of a burner that has been switched ON:
Only for dual burners: A fuel type has been pre-selected in the fuel selection image.
Page 2 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
The safety chain has closed without fault.
No burner fault is displayed.
The burner control circuit is closed, i.e. all boiler and burner requirements for a burner start are fulfilled (e.g. flue gas
valve open, air intake valve open, burner side leak tightness control positive, etc.).
Only for hot water generators: The minimum flow through boiler and, if applicable, flue-gas heat exchanger exists.
Only for hot water generators and undershooting of the minimum boiler return flow temperature: Return flow
temperature monitoring has been deactivated (see Operating Instructions G316 to G319).
Only for steam generators: The pressure signal is within the measurement range.
Only for hot water generators: The temperature signal for boiler supply flow and boiler return flow temperature is within
the measurement range.
Only for steam generators: Boiler pressure < burner start-up pressure PBE.
Only for hot water generators: Boiler temperature < burner start-up temperature TBE.
The following cases must be distinguished for burner start:
Only one of the burners has been switched ON: In this case only this burner starts. On the LBC touch panel, a flame
appears in front of the burner.
Both burners have been switched on and are operated in parallel: In this case both burners start. Flames appear in front
of both burners on the LBC touch panel. If one of the burners does not meet the above-mentioned requirements, only
the other burner starts.
Both burners have been switched ON, one of the burners is the primary burner, the other one is the secondary burner.
In this case, first only the primary burner starts. A flame appears in front of the primary burner on the LBC touch panel. If
the primary burner does not meet the above-mentioned requirements, the secondary burner starts (and becomes
primary burner).
6.4
Automatic light load and subsequent control operation
When the burner starts operating, an automatic timer limits the burner load to low load (preset to a light load time T_LL of
180 seconds, performance regulation can be modified by Loos Service). This prevents uncontrolled switching on and off of
the burner in case of low heat requirement. This automatic mechanism prevents unnecessary pre-ventilation losses and
protects the boiler and burner components.
Note: Each time a burner is switched on via the burner control (not in case of an automatic burner start after
normal shut-down) and after each fault the control must additionally be released in the performance regulation
image of the LBC touch panel (high load with two or three-stage burners, automatic with infinitely variable
burners) as otherwise the burner would only be operated in low load.
After the low load time has elapsed and performance regulation has been released, the burner is controlled in accordance
with the set mean operating pressure PM with steam generators or the set mean supply flow temperature TVM with hot
water generators.
Burner sequence control:
When a burner has been selected as primary burner, first only the primary burner starts. The system requests the secondary
burner when the load reaches the secondary burner switch-on value (pre-set at 70%, changeable by Loos Service).
In order to avoid excessive switching on and off, a specified delay time for switching on the secondary burner has been
programmed (pre-set at 60 sec., changeable in the performance control by Loos Service). As both burner controls receive
the same load requests, after a short period of time both burners have the same load setting.
Page 3 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
6.5
Burner cut-out in normal operation
The following cases must be distinguished:
Only one burner in operation or both burners in parallel operation: The system carries out a normal shut-down with
steam generators when the boiler pressure reaches the burner cut-out pressure PBA or with hot water generators when
the supply flow temperature reaches the burner cut-out temperature TBA. The flames in front of the burners on the LBC
touch panel disappear, the burner switches stay in the ON position.
Both burners are in operation, one of the burners is the primary burner, the other one is the secondary burner. If the
load drops under the switch-on value for secondary burners, first of all both burners control the low load position. After a
specified delay time (preset at 60 seconds, performance regulation changeable by Loos Service) has elapsed the
system switches off the secondary burner. The flame in front of the burner on the LBC touch panel disappears, the
burner switch remains in the ON position.
The primary burner switches off with a normal shutdown with steam generators when the boiler pressure reaches the
burner cutout pressure PBA or with hot water generators when the supply flow temperature reaches the burner cutout
temperature TBA. The flame in front of the primary burner on the LBC touch panel disappears, the burner switch
remains in the ON position.
6.6
Controlled shut-down
Firing switch image: When touching the shutdown symbol in the firing switch picture of the LBC touch panel, both
burners are automatically driven into the low load position from any load stage. The burners switch off 120 seconds
after the shutdown symbol has been touched, when the burner cutout pressure PBA of steam generators is reached or
when the burner cut-off temperature TBA of hot water generators is reached. The system automatically sets the burner
switch and the firing switch at OFF.
Burner control image: When touching the shutdown symbol in one of the burner control images of the LBC touch
panel, the system automatically drives the corresponding burner into the low load position from any load stage. The
burner switches off 120 seconds after the shutdown symbol has been touched, when the burner cutout pressure PBA
of steam generators is reached or when the burner cut-off temperature TBA of hot water generators is reached. The
system automatically sets the burner switch in OFF position.
If one of the burners is primary burner and the other one is secondary burner, shutting-down is, however, only possible
in the following order: secondary burner first and then primary burner. First only the shutdown symbol for the secondary
burner can be selected on the LBC touch panel. The shutdown symbol for the primary burner cannot be selected until
the burner switch of the secondary burner is in the OFF position.
Automatic shutdown can be interrupted and switched to normal operation in the period between touching the shutdown
symbol and automatic switch-off by touching the ON symbol. Switchover is effected without shocks.
Note: Independent from the described procedure, the firing / a burner can be switched to OFF in any load
position. However, the consequence could be that with gas operation, due to the dynamic pressure in the gas
supply line, the gas safety shut-off valve closes automatically and must be unlocked manually before a new
burner start.
6.7
6.7.1
Faults
Boiler faults
In case of boiler faults, firing is switched off and blocked via the safety chain. During that process the firing switch is
automatically set from the ON to the OFF position. A fault message appears on the LBC touch panel and is registered in the
event memory. The fault is indicated acoustically by a continuous tone.
To start the firing process, the system must be deblocked with the deblocking button at the boiler control cabinet.
Subsequently, firing and both burner switches must be switched on again in the firing dialogue of the LBC touch panel (see
chapter 6.3).
Page 4 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
6.7.2
Burner fault
In case of burner faults the burner switch is automatically set from the ON to the OFF position. A fault message appears on
the LBC touch panel and is registered in the event memory. The fault is indicated acoustically by a continuous tone.
The fault is displayed separately for each burner; in case of a burner fault the system switches over to the other burner
automatically (see chapter 6.2).
For restart of the faulty burner, actuate the deblocking device at the burner control and switch on the burner switch in the
burner control image of the LBC touch panel subsequently.
Operation
The basic operating principles for the LBC touch panel are described in the operating instructions G300 for steam
generators / the operating instructions G301 for hot water generators, chapter Description of Structure and Functions /
Description of Process.
7.1
Burner sequence control
The following images show the burner sequence control selection:

With steam generators
or
hot water generators
or
Figure 1: Firing dialogue selection
Figure 2: Burner sequence control selection
Burner sequence control

Field 1:
Not allocated
Page 5 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
Field 2 / 3:
Information on the fuel quantity in burner 1/burner 2 (e.g. 1000 m/h / 200 l/h), if measurement with
transducer is part of the order
Field 4:
Information on burner sequence control (e.g.
Field 5 / 6:
Information on performance regulation (e.g. actual value 8.2 bar, setpoint 12.6 bar)
= burner 1 primary, burner 2 secondary)
Actions:
Burner 1 and burner 2 in parallel operation
7.2
Firing switch
The following images display the firing switch selection:

or
Hot water boilers:
or
Figure 4: Firing switch selection
Firing switch
Page 6 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)

Field 1:
Not allocated
Field 2 / 3:
Information on the fuel quantity in burner 1/burner 2 (e.g. 1000 m/h / 200 l/h), if measurement with
transducer is part of the order
Field 4:
Information on burner sequence control (e.g.
Field 5 / 6:
= burner 1 primary, burner 2 secondary)
Actions:
Switches firing off
Switches firing on (if firing is not blocked by the safety chain)

Controlled shut-down of the complete firing from any burner load position into low load
position with subsequent switch-off
Page 7 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
7.3
Burner control
or
Hot water boilers:
or
Figure 6: Burner selection
Selection of burner 1
Figure 7: Burner control selection
Burner control of burner 1

Field 1:
Not allocated
Field 2:
Current load preset by control unit, e.g. 10%
Page 8 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
Field 3:
Current load burner of selected burner, e.g. 60%, if load setting indication is included in the order
Field 4:
Not allocated
Field 5 / 6:
Actions:
Switches burner off
Switches burner on (if firing is not blocked by the safety chain)

Controlled shutting-down from any load position in low load position with subsequent shutdown (for primary burners only if secondary burner has already been switched off)
repair:
Observation/Fault:
Code 7 Continuous tone Interlock system (boiler fault)
Cause
Repair

limiters


Observation/fault:

By whom?
Burner fault left (ZFR)

Burner fault right (ZFR)
Cause
Repair

instructions
By whom?
Page 9 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
Observation/fault:
Code 61
Sensor breakdown, pressure transmitter for steam generators
Cause
Repair
Check connection cables, measurement transducer

feed and measurement transducer, measurement
signal must be in the range 4...20mA
By whom?
A vacuum has been created in the boiler by cooling, Briefly allow air into boiler to remove vacuum
and the measurement range of the pressure
transducer is therefore not reached
Observation/fault:
Code 108 - Continuous tone Temperature blow min. return flow tempreature for hot
water generators
Cause
Repair
Observation/fault:
Code 130 Burner preset waiting time
Cause
Repair
Burner is not operating despite preset waiting time

has elapsed
Check start prevention, also see burner does not

start Observation/Fault
Observation/fault:
By whom?
By whom?
Code 160 Return flow temperature transducer for hot water generators sensor
breakdown
Cause
Repair

range 4...20mA
By whom?
Page 10 of 11
Burner control
for Shell Boilers
G361
Version 1 (10/08)
Observation/fault:
Code 161 Sensor breakdown, supply flow temperature transducer for hot water
generators
Cause
Repair

range 4...20mA
Observation/fault:
By whom?
Burner does not start
Cause
Repair
With dual burners, the fuel selector switch is in the

OFF position
Preselect fuel with fuel selector switch
Switch burner switch on
Burner fault
Repair burner fault and deblock with deblocking

device at burner or at boiler control cabinet
Boiler fault
Repair boiler fault and deblock with deblock button

at boiler control cabinet
Flue gas valve not opened
Check function of fuel gas valve
Air intake valve not opened
Check function of air intake valve
Sensor failure, pressure transducer (Code 61)
see Code 61
Return flow temperature transducer sensor

See code 160
Supply flow temperature transducer sensor

See code 161
Minimum boiler return flow temperature of hot water

boilers undershot
Reduce heat intake from network
Boiler circuit pump, lifting pump or FHE pump of hot

water generators is defective or switched off
Repair defective boiler circuit pump, lifting pump or

FHE pump or switch on pump if applicable
No minimum flow of hot water boiler
Increase flow
By whom?
Page 11 of 11

G381
Version 1 (10/07)
Contents
1
Safety .......................................................................................................................................................................... 1
6.1
General ........................................................................................................................................................................ 2
6.2
Automatic operation ..................................................................................................................................................... 2
6.3
Manual operation ......................................................................................................................................................... 2
6.4
Controlling a return flow shut-off valve controlled by the client..................................................................................... 2
Operation .................................................................................................................................................................... 3
Safety
Page 1 of 5

G381
Version 1 (10/07)
6.1
General
To be able to control the energy given off by the boiler depending on the different operating conditions, a shut-off valve is
built into the boiler's return flow. This separates the boiler from the hot water network.
6.2
Automatic operation
In automatic mode, the controlled return flow shut-off valve is released as a function of the following opeating conditions.
When automatically started up the boiler reaches its mean forward flow temperature TVN the first time.
In manual mode, the boiler reaches its mean forward flow temperature the first time time after the burner is switched on.
In automatic mode, the controlled return flow shut-off valve is not released in the following operating conditions:
above points not yet fulfilled
Heat maintenance (see G398) has been preselected for the boiler.
The boiler has a fault which is preventing the burner from starting.
(The system closes the return flow shut-off valve 5 minutes after a fault has occurred in order to avoid undefined
network supply flow temperatures.)
Fault message:
If the controlled return flow shut-off valve has not been released and if it does not close after expiry of a preset waiting time
TK (preset at 180 sec., changeable by Loos Service), a fault alarm will be displayed on the LBC touch panel and registered
in the event memory. The fault is indicated acoustically by an intermittent sound.
6.3
Manual operation
The return flow shut-off valve can be opened and shut. The control of the return flow shut-off valve as a function of operating
conditions does not function in manual mode.
Note: If the controlled return flow shut-off valve is opened by hand, there is a risk in Heat Maintenance mode
that the boiler could cool down.
6.4
Controlling a return flow shut-off valve controlled by the client
In this case, the LBC only releases the return flow shut-off valve or withdraws the release. The control of the return flow
shut-off valve must be incorporated in the client's controls. The limit position positions of the client's control must be given to
the LBC. Observe the Technical Information TI033 with regard to signal exchange.
For boiler systems which are fitted with the preconditions for operation via CIC (central instrumentation and control), (floating
contacts, signal separator or connection to Profibus DP), the possibilities are as follows:
Release of the return flow shut-off valve as binary contact or via Profibus DP to the CIC
Feedback of the limit position of the return flow shut-off valve as binary contact or via Profibus DP from the CIC
Page 2 of 5

G381
Version 1 (10/07)
Operation
The following figures show the return flow shut-off valve selection:
or
Figure 2: Return flow shut-off valve selection
or
Figure 3: Return flow shut-off valve control
Page 3 of 5

G381
Version 1 (10/07)

Field 1:
Field 2:
Current network return flow temperature, e.g. 50C, or mean boiler return flow temperature, setpoint TRM,
e.g. 55C
Field 3:
Mean boiler return flow temperature, setpoint TRM, e.g. 55C, or not allocated
Field 4:
Return flow shut-off valve position:

=
Final position return flow shut-off valve OPEN reached
Return flow shut-off valve opens, no final position reached
(No display) =
return flow shut-off valve not triggered, no final position reached
Return flow shut-off valve closes, no final position reached
Final position return flow shut-off valve CLOSED reached
Field 5:
Not allocated
Field 6:
Current lifting pump operating mode:

=
Automatic mode
Manual mode
Switched off
or current lifting pump speed, e.g. 100%
Actions:
Manual opening of the return flow shut-off valve (as long as the field is being touched)
Manual closing of the return flow shut-off valve (as long as the field is being touched)
Activation of automatic operating mode
Note: In case of a client-controlled return flow shut-off valve the LBC only activates or deactivates release of the
return flow shut-off valve.
Page 4 of 5

G381
Version 1 (10/07)
repair:
Observation/fault:
Code 138 Intermittent tone Running time error, return flow shutoff valve
Cause
Repair
Return flow shutoff valve hasn't closed, although no

release given
Compare the actual running time of the shutoff

valve motor with the time entered in the LBC (set
time in LBC approx. 30 seconds more)
Limit switch not switched
Check setting of limit switch for closed position

locally
By whom?
Page 5 of 5
Control panel components
Switching amplifier B 3
for level limitation with electrode, self-monitoring, TV* component-tested
H001
Version 4 (09/09)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Construction ................................................................................................................................................................. 3
6.2
Function ....................................................................................................................................................................... 4
8.1
8.2
Interim storage ............................................................................................................................................................. 5
Assembly .................................................................................................................................................................... 5
10
10.1
Electrical connection between mounting amplifier and level limiter electrode .............................................................. 6
10.2
Switching amplifier connection diagram ....................................................................................................................... 6
11
12
Start-up ....................................................................................................................................................................... 9
13
Operation .................................................................................................................................................................... 9
14
Shutting down ............................................................................................................................................................ 9
15
16
Care and Maintenance ............................................................................................................................................. 10
16.1.1 Operating test on boiler systems with a level limiter electrode ................................................................................... 10
16.1.2 Operating test on boiler systems with two level limiter electrodes.............................................................................. 11
17
Replacement Parts ................................................................................................................................................... 11
Page 1 of 11
H001
Version 4 (09/09)
I001 Level limiter electrode
The B3 switching amplifier may only be used in conjunction with the E3 or E4B level limiter electrode (see Operating
Instructions I001) for limiting the level in shell boilers with a boiler water conductivity of 30 S/cm (based on 25C).
The switching amplifier may only be installed in housings with a degree of protection IP 44 and only used within the
framework of the operating conditions outlined in the "Technical Data" chapter.
Any other operation is contrary to the intended use and therefore forbidden.
Safety
Danger! A malfunction of the level limiter electrode could lead to serious damage and loss of human life or serious
injury and, as a consequence of this, to serious physical injury or death of people in the vicinity of the boiler due to
leakage of the hot medium.
The level limiter device is a device that is of absolute fundamental importance for the safety of the boiler system.
For safety reasons, work on such safety devices should only be carried out by Loos International or specialist
staff authorised by Loos International.
Page 2 of 11
H001
Version 4 (09/09)
6
6.1

Construction
1
Plug-in card in a 19" plug-in unit
Electrode test button
Insulation monitoring test button
Operating signal light
M250/0.08 amp micro-fuse (labelled

80mA on the plug-in card)
Grip handle
2
3
4
5
Figure 1: B3 switching amplifier
The B3 switching amplifier is mounted on a mounting rack.

Mounting rack type
9 TE
18 TE
B1
84 mm
130 mm
B2
76 mm
122 mm
B3
67 mm
113 mm
Installation depth
215 mm
215 mm
390 g
472 g
Transportation
weight
Use
Number of level limiter electrodes in

boiler control
1
1: Terminal strip
Figure 2: Mounting rack for B3 switching amplifier
Page 3 of 11
H001
Version 4 (09/09)
6.2
Function
The B3 switching amplifier, in conjunction with the E3 or E4B level limiter electrode (see Operating Instructions I001), is a
specially designed water limiter with insulation monitoring. This combination is used to detect the minimal permissible lowwater level in steam and hot water generators. Its mode of operation is based on the difference in conductivities of water and
steam.
When the level limiter electrode emerges from water, the output relay of the switching amplifier drops out and there is a
shut-down. A delay circuit ( 20 sec) eliminates short-term water level fluctuations, thereby preventing undesired shutdowns.
The switching point of the level limiter is determined by the place of installation, position and rod length of the level
limiter electrode. Please see the Assembly and Commissioning chapters in Operating Instructions I001 in relation to
this.
The level limiter has insulation monitoring. In the case of an insulation error between the electrode rod and earth, the
output relay of the switching amplifier drops out, causing a shut-down.
The limiter is self-monitoring. If errors arise in the automated test procedure, the output relay of the switching amplifier
drops out and there is a shut-down.
Control elements:
A lack of water can be simulated using the electrode test button (2). Once the delay period has elapsed ( 20 sec), this
causes a drop-out in the output relay and thus a shut-down.
Important! The test button must be constantly pressed for a period of 20 seconds to trigger the electrode test.
An insulation error (conductive lining) can be simulated between the electrode and insulation monitoring sleeve via the
insulation monitoring test button (3). This also effects a shut-down once the delay period has elapsed ( 20 sec).
The operating signal light (4) lights up for an activated output relay, thereby signalling that the level of water in the boiler
is sufficient.
The micro-fuse (5) serves to protect the switching amplifier on the grid side. If it needs to be replaced, it should only be
replaced with an M 250/0.08 amp medium time lag fuse.
Important! By integrating the switching amplifier into the boiler safety chain, the external downstream safety
relay will drop out if the switching amplifier is shut down and the firing locked. The boiler safety chains unlock
button must be pressed before recommissioning can take place.
Dimensions:
19 plug-in card
Weight:
525 g
Supply voltage:
230 V AC (+10%, -15%)
Power consumption
approx 4,5 VA
Frequency:
50/60 Hz
Electrical switching capacity:
250 V AC, 4 A
Fuse:
2 A medium time lag
Degree of protection:
IP 20
Ambient temperature:
0 ... + 60 C
Page 4 of 11
H001
Version 4 (09/09)
Air pressure:
785 - 1085 hPa (equivalent to a height of up to 2000 m)
Relative air humidity during operation: 10 - 95% without condensation

Approvals:
8
8.1
Germany
TV-WB 07-365
France
D15/88.17.0 (CETEN APAVE)
Austria
TV - W - WB - 88-20916 (with VLK2)
Switzerland
92.5 51899.01
Hungary
AEEF 9660-BE

Electronic measurement, control and regulating equipment are packed at the factory to be sufficiently protected and suitable
for transport.
Please note the following instructions:
Never expose the equipment to temperatures below -40 C or above +60 C.
Always protect equipment against moisture and the effects of damp.
Store all equipment in its original packaging.
If damage to the packaging is found when the delivery is received, the driver should be informed of the damage. When
the delivery is handed over by the driver, he must confirm the damage to the packaging in writing on the delivery receipt
slip.
If damage is found after unpacking, please contact Loos International immediately.
Note: Pay attention that no humidity deposits at or in the system (condensation) after transporting the
subassemblies at low temperatures or after extreme temperature fluctuations.
Adjust the subassembly to the room temperature before commissioning. Do not expose the subassemblies to
direct radiation of a heating unit. When thawing the subassemblies, wait until they have dried completely and do
not switch them on before a waiting period of approx. 4 hours has expired.
8.2
Interim storage
All equipment should be stored in the original packing.
Store in dry (humidity < 60%), dust-free conditions
Temperature fluctuation in the store room < 10 K/h
Under no circumstances should the devices be exposed to temperatures below -40 C or above +60 C.
Assembly
The low water level limiter is fundamentally important to the safety of the boiler system. For safety reasons, work
on such safety devices may only be carried out by qualified personnel from Loos International or individuals
authorised by Loos International.
Danger: Risk of fatal injury through electric current! The subassemblies should never be assembled or
disassembled when the power supply to the system or the control cabinet is switched on. Danger of fatal injury.
In addition to this the subassemblies may be completely destroyed.
Page 5 of 11
H001
Version 4 (09/09)
Attention! The subassembly is an open electric operating unit. It should only be installed in a closed control
cabinet. Only instructed and authorised personnel should be allowed access.
Turn off the power to the unit/control cabinet!
The switching amplifier may only be mounted to the intended coded slot in the 19 mounting rack.
The switching amplifiers plug-in card may only be handled by the grip handle (6) in order to avoid damaging the
electrical components on the plug-in card.
The order-related setup instructions for the respective control cabinet must be taken into account.
It must be ensured that there is still enough room for the heat dispersal of the subassembly.
Important! The electrical connection is part of the component testing. The component testing will expire if the
required connection guidelines are not adhered to. The electrical connection of the switching amplifier should
only be carried out by Loos Service personnel or a certified electrician.
10.1 Electrical connection between mounting amplifier and level limiter electrode
The electrical connection between the boiler control cabinet and level limiter electrode must be undertaken via a shielded
cable in the case of the E4B electrode or via a silicone cable in the case of the E3 electrode, the whole length of which is
drawn into flexible metal tubing. The precise specification can be found in Operating Instructions I001, which must be
adhered to.
10.2 Switching amplifier connection diagram

The following switching amplifier connection diagram must be strictly adhered to (depending on the boiler control cabinet
design with one or two level limiter electrodes or switching amplifier).
Page 6 of 11
H001
Version 4 (09/09)
Emergency
Operation
Safety chain
Water level limiter

Mounting rack
Operation
Deblocking
safety chain
P1
Electrode test
L > NW
Water level above low water level (NW)
P2
Insulation monitoring test
L
= Water level at low water level (NW)
1550
OPT
Connection option
Figure 3: B3 level limiter electrode connection diagram when using one limiter device in the boiler
control
Page 7 of 11
H001
Version 4 (09/09)
Emergency
Operation
Water level limiter 1
Water level limiter 2
Mounting rack
Operation
Betrieb
P1
Electrode test
L > NW
P2
Insulation monitoring test
L
= Water level at low water level (NW)
1550
Safety chain
Mounting rack
Water level above low water level (NW)
Figure 4: B3 level limiter electrode connection diagram according to EN 12953 when using two limiter
devices in
the boiler control

The switching point of the low water level limiter is determined by the place of installation, position and rod length of the level
limiter electrode. Please see the Assembly and Commissioning chapters of Operating Instructions I001 in relation to this.
The switching amplifier does not need to be set up or adjusted.
Page 8 of 11
H001
Version 4 (09/09)
12 Start-up
All of the low water level limiters in the boiler system must be tested during commissioning (usually two limiters in a steam
boiler, just one limiter in a hot water boiler).
For information on how to test the switching point, please see the "Commissioning" chapter in Operating Instructions I001.
13 Operation
Note: Please observe the instructions in Chapter 13 Operation of Operating Instructions I001.
14 Shutting down
The disassembled subassembly must be disposed of in accordance with the respective applicable environmental protection
regulations such that the subassembly cannot cause any danger to the environment.

repair:
Observation/fault:
Operating signal light does not light
Cause
Repair
Shut-down on fault of the low water level limiter
See Operating Instructions I001
Outage of the switching amplifiers power supply
Check the power supply
By whom?
Switching amplifier electrode connection line defect Check the connection line, clamping points, plug
connection (E4B electrode) and insulation of the
line (E3 electrode)
Defective M250/0.08 A medium time lag micro-fuse
of the switching amplifier
Replace the M250/0.08 A medium time lag microfuse
Self-monitoring of the level limiter has responded
Replace the switching amplifier
Defective switching amplifier
Replace the switching amplifier
Defective level limiter electrode
See Operating Instructions I001; possibly replace

the level limiter electrode
Page 9 of 11
H001
Version 4 (09/09)
Observation/fault:
Low-water level limiter does not trigger a shut-down on fault during testing in
accordance with the chapter 16
Cause
Repair
Protective tube of the level limiter electrode soiled
Clean the boiler and protective tube
By whom?
Adjust boiler water in accordance with Operating

Instructions B002 Water Quality Guideline
The rod of the level limiter electrode is lying against
the protective tube
Check the installation location and troubleshoot
Short-circuit in the cable connecting the control

cabinet and level limiter electrode
Establish and remove the cause of the short-circuit
Danger! A malfunction of the low water level limiter could cause extreme damage to the boiler and, as a
consequence thereof, serious physical injury or death of people in the vicinity of the boiler due to leakage of the
hot medium. Therefore, the level of the water should be reduced following replacement of the switching amplifier
or electrode in order to make sure that they are working properly.

The switching amplifier is maintenance-free. It cannot and should not be repaired on site. If the subassembly is discovered
to be defective, it should be replaced with a new one. The dismantled subassembly should be sent to Loos International.
Danger: Once the switching amplifier has been replaced, the boiler water level should be reduced to check that
it is working properly (see the Maintenance and Care chapter).
An operating test on the entire E3 or E4B level limiter electrode and B3 switching amplifier system must be carried out
monthly. An operating test of the entire water level monitoring system should be carried out by reducing the level of water.
Please read Operating Instructions I001 Level Limiter Electrode on this, especially the Operating Test of the Level Limiter
Electrode chapter.
16.1.1 Operating test on boiler systems with a level limiter electrode

By lowering the water level below the switching point of the level limiter electrode, a switching operation is carried out by the
level limiter electrode. The Operating signal light (4) on the switching amplifier of the level limiter electrode should go out
and there should be a shut-down on fault of the boiler control.
If there is no shut-down on fault, the boiler must be taken out of operation immediately and the cause of the failure
established.
repaired.
Page 10 of 11
H001
Version 4 (09/09)
16.1.2 Operating test on boiler systems with two level limiter electrodes
By lowering the water level below the switching point of the level limiter electrodes, one level limiter electrode will first
respond. The Operating signal light (4) on the switching amplifier of this level limiter electrode should go out and there
should be a shut-down on fault of the boiler control.
The water level must be lowered further until the Operating signal light (4) also goes out on the second switching amplifier.
In order to test the functioning of the second level limiter electrode and its switching amplifier, the following steps should be
taken following recommissioning of the boiler following the shut-down on fault.
The Electrode test button (2) must be pressed until the green "Operating" signal light (4) goes out. There should be a
shut-down on fault of the boiler control.
The boiler should be recommissioned.
If there is no shut-down on fault, the boiler must be taken out of operation immediately and the cause of the failure
established.
repaired.
M 250/0.08 A micro-fuses for switching amplifiers - 10 units:
Material no.
003043.1
B3 switching amplifier:
Material no.
801228.2
Page 11 of 11
Operating and Monitoring System

TP10
H024
Version 1 (10/07)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Construction................................................................................................................................................................. 2
6.2
Operation ..................................................................................................................................................................... 2
Assembly.................................................................................................................................................................... 4
9.1
Replacing the system .................................................................................................................................................. 4
9.2
Mechanical installation................................................................................................................................................. 4
9.3
Electrical installation .................................................................................................................................................... 5
9.3.1
Interfaces ..................................................................................................................................................................... 6
9.3.2
Connection sequence .................................................................................................................................................. 6
9.3.3
Equipotential bonding .................................................................................................................................................. 6
9.3.4
Power supply ............................................................................................................................................................... 7
9.3.5
Control ......................................................................................................................................................................... 7
10
Start-up ....................................................................................................................................................................... 7
10.1
Initial start-up ............................................................................................................................................................... 7
10.2
Loading the operating program update ........................................................................................................................ 8
11
Shutting down.......................................................................................................................................................... 10
12
13
14
Replacement Parts .................................................................................................................................................. 11
The Operating and Monitoring System supplied by Loos International is solely intended for the operation and monitoring of
boiler systems within the scope of Loos Boiler Control LBC or Loos System Control LSC.
The Operating and Monitoring System may only be installed in enclosed switching panels or in the doors of closed
switchgear cabinets and may only be used within the scope of the Operating Conditions (see Chapter 7).
Any other operation is not operation for the intended use and is thus not allowed.
Page 1 of 11

TP10
H024
Version 1 (10/07)
Safety
6
6.1

Construction
MMC slot
(MultiMediaCard)
Touch screen
Installation seal
Openings for
wedge clamps
Figure 1: Front view
Side view
Rating plate
MMC slot
DIL switch
Equipotential
bonding connection
Interfaces
Figure 2: Back view
6.2
Underneath view
Operation
You operate the Operating and Monitoring System with the Touch Screen. All the necessary operating devices are
displayed on the Touch Screen after it has powered up (see Operating Instructions G300, G301, G400 or G401).
Page 2 of 11

TP10
H024
Version 1 (10/07)
The rating plate is on the back of the system.
All dimensions in mm
Tolerance 1 mm
Figure 3: Dimensions
Weight
approx. 2650 g
Display data
640 x 480 pixel, 65 536 colours, TFT
Supply voltage
Safety low voltage, SELV
Permitted range:
20.4 VDC ... 28.8 VDC
Power take-up (IN) typ./max:
approx. 700 mA / approx. 1100 mA
Power loss:
17 W
Type of protection:
Front: IP65 (built-in)

Housing: IP20
Operation with vertical installation: 0 ... + 50 C

Operation with tilted installation up to 35: 0 ... + 40 C
Rated value (UN): 24 VDC
Relative air humidity in operation: 10 ... 90% without condensation

Power failure:
In the event of a power failure the program and user data are saved.
Application memory:
6 MByte
Page 3 of 11

TP10
H024
Version 1 (10/07)
The Operating and Monitoring System is adequately packed and protected ex works. During transportation and storage
ensure that the components are transported and stored in a dry state and that the environmental conditions are as
specified.
Type of condition
Permitted range
Free fall (in transport packaging)
1m
Temperature
20C to +60C
Air pressure
1080 to 660 hPa (corresponds to a height of -1000 to 3500 m)
Relative humidity
10 to 90 %, no condensation
Sinusoidal oscillations as spec. in

IEC 60068-2-6
5 9 Hz: 3.5 mm,
Impact as spec. in IEC 60068-2-29
250 m/s, 6 ms, 1000 shocks
9 500 Hz: 9.8 m/s2
Note: After transporting the Operating and Monitoring System at low temperature or after extreme temperature
fluctuations, please make sure that there is no moisture on or in the system (condensation).
Before commissioning, you must bring the Operating and Monitoring System to room temperature. In doing so,
do not expose the system to direct radiated heat from a heater. In the case of condensation, you should only
switch the system on after it has completely dried after a waiting time of approx. 4 hours.
Assembly
Work on the Operating and Monitoring System and all parts connected with it may only be carried out by
competent persons, i.e. trained electrical specialists who have the appropriate specialist knowledge of the
assembly of electronic components, especially stored program controllers.
9.1
Replacing the system
The Operating and Monitoring System cannot be repaired in situ. If it is found that the system is faulty, it must be replaced
with a new one. The system that has been removed must be sent back to Loos International.
Mechanical and electrical installation is described in the following sections.
The sequence for removing the system is the opposite to that for installing it.
9.2
Mechanical installation
Danger! Danger of fatal injury from electric current! The Operating and Monitoring System may not be installed
or removed if the system or the switchgear cabinet are connected to the power. This could cause fatal injuries. In
addition, the System could be completely destroyed.
Preconditions:
The Operating and Monitoring System is prepared for permanent vertical or angled installation in closed switching
panels or in the doors or closed switchgear cabinets (deviation from vertical 35).
Installation opening: width: 310+1 mm, height: 248+1 mm, depth: 61 mm
Page 4 of 11

TP10
H024
Version 1 (10/07)
The following spaces must be left at the sides of the system:
50 mm above and below the installation opening, for ventilation
15 mm to the right and left of the installation opening to insert the wedge clamps during installation
At least 10 mm at the back, in addition to the installation opening for the Operating and Monitoring System
The system must be mounted in such a way that it is protected against direct sunlight.
Installation:
Before starting the installation work, make sure that the control cabinet is cut off from the power supply!
Remove all packaging and protective films from the Operating and Monitoring System.
Check the installation seal. If it is damaged, please order a new replacement seal. Do not twist the installation seal as
you fit it. This can lead to leaks at the installation opening.
Insert the Operating and Monitoring System into the installation opening from the front.
For the installation, you will need the 12 wedge clamps from the accessories pack. The following table gives the
position of the wedge clamps. Count from left to right and from top to bottom. The position indicated corresponds to the
first occupied opening for the wedge clamp in the direction of counting. With the TP 10, you can only use every second
opening for fixing the wedge clamp. The wedge clamp covers several openings when it is installed.
Side
Position of wedge clamp

1

2

3
top and bottom
11
20
right and left
16
Insert a wedge clamp into an opening at the Operating and Monitoring System.
Figure 4: Inserting the wedge clamp
Fix the wedge clamp by tightening the cross-head screw. The maximum permitted torque is 0.2 Nm.
Repeat the stages until all the wedge clamps are fixed.
At the front, check the position of the installation seal. It should not project at the Operating and Monitoring System.
9.3
Electrical installation
Precondition:
The Operating and Monitoring System must be installed in accordance with the Operating Instructions above.
General notes:
Make sure that the existing wiring is in accordance with the accepted electrotechnical rules and the valid standards.
Page 5 of 11

TP10
H024
Version 1 (10/07)
During installation and operation of the system, the valid national and regional regulations must be strictly complied
with. These regulations and requirements can be obtained, if necessary, from the competent local authorities.
Only cables may be used which are dimensioned according to the accepted electrical rules in such a way that a
sufficient power supply is ensured. Please make sure that the power supply cables are not warmed to any extent that is
not permitted.
The cable cross-section of all signalling cables must be such that a signal flow of the necessary strength is always
guaranteed.
Please only used screened standard cables.
Always tighten screws sufficiently.
All cables should be laid in such a way that the cable paths are kept as short as possible in accordance with the valid
regulations.
Mains cables must be laid in accordance with the accepted electrotechnical and electronics regulations.
9.3.1
Interfaces
2 x USB
Ethernet
RS422 / RS485
Power supply
Figure 5: Interfaces
The connection for the equipotential bonding is on the back of the TP10 (see Figure 2)
9.3.2
Connection sequence
Attention! Please follow this connection sequence!
Failure to do so can cause damage to the system.
1. Equipotential bonding (see Chapter 9.3.3)

2. Power supply (see Chapter 9.3.4)
3. Control (see Chapter 9.3.5)
Attention! If you are connecting external devices with 230 V power supply to the USB interface, you must
ensure that the system is a non-floating system.
To remove, separate the system from the connections in the reverse order!
9.3.3
Equipotential bonding
Differences in potential may occur between parts of the system that are spatially separated. Potential differences can also
be caused by different mains supplies. These potential difference can lead to high balancing currents via the data cables
and thus to the destruction of the interfaces. Balancing currents can arise in particular if cable screens are applied on both
sides and earthed on different parts of the system.
Potential differences must be reduced as far as possible by the use of equipotential bonding cables so that the electronic
components work perfectly.
Please note the following when setting up equipotential bonding:
The greater the cross-section of the equipotential bonding cable, the more effective the equipotential bonding is.
The cross-section of an equipotential bonding must be dimensioned for the maximum balancing current.
Page 6 of 11

TP10
H024
Version 1 (10/07)
Between switchgear cabinets, equipotential bonding cables with a minimum cross-section of 16 mm have proved
successful in practice.
Use equipotential bonding cables made from copper or galvanised steel.
Use the equipotential bonding cables over a large area with the earth/protective conductor and protect the connection
against corrosion.
Lay the equipotential bonding and data cables in parallel and as close as possible to each other.
Cable screens are not suitable for equipotential bonding!
9.3.4
Power supply
The terminal strip to connect the supply voltage is contained in the additional package. It is designed for cables with a
max. cross-section of 1.5 mm.
Make sure that the cables are not connected the wrong way round; they should be:.
GND
+ 24 V DC
Only tighten the screws if the terminal strip has been pulled up. Otherwise, the pressure of the screwdriver could
damage the slide-on bushing in the system.
Carry out a switching-on test to make sure that the power supply has been connected with the poles the right way
round.
Note:
For non-floating system design:

Connect the power supply outlet for GND 24 V to the equipotential bonding.
Select a connection point that is as central as possible.
9.3.5
Control
The control is connected via the RS485 interface (MPI bus).

The DIL switch (on the back of the Operating and Monitoring System) for the configuration of the RS-422/RS-485 interface
.
is set in the delivery state for communication with the control via RS485m, switch position:
All connections via the MPI bus are to be made in accordance with the order-specific circuit diagram for the associated
control cabinet. In particular, make sure that the termination impedance in the plugs is set properly. In general, with a bus
cable in the MPI plug, the slide switch in the plug should be ON, and with two bus cables in the MPI plug, the slide switch
should be at OFF.
10 Start-up
Work on the Operating and Monitoring System and all parts connected with it may only be carried out by
competent persons, i.e. trained electrical specialists who have the appropriate specialist knowledge of the
assembly of electronic components, especially stored program controllers.
Preconditions for commissioning:

The Operating and Monitoring System is installed and electrically connected in accordance with the Operating Instructions
provided..
Switch on the power supply.
After switching on, the screen comes on. During the start-up process, various images and messages are displayed,
including a white screen or Windows Desktop at times. Do not try to operating anything from this Desktop.
Page 7 of 11

TP10
H024
Version 1 (10/07)
If the Operating and Monitoring System does not start up, it may be that the wires at the terminal strip are the wrong
way round. Check the wires and change the way they are connected.
After starting the operating system, the Loader screen is shown temporarily:
Figure 6: Loader
The operating program is normally loaded at the factory and is started after a short delay without any action on behalf of
the operator; if not, press Start on the Loader.
If there are any problems starting up, e.g. operating mode Transfer is started, stop, using Cancel, if possible and
contact Loos International immediately.
10.2 Loading the operating program update

Operating program updates are loaded from a MMC (MultiMediaCard) which you can obtain from Loos International.
Attention! MMCs that are not supplied by Loos International may not be used any circumstances. Failure to
comply with this requirement may cause destruction of the system!
Attention! Never remove the MMC from the Operating and Monitoring System whilst data re being accessed,
since this could destroy data on the MMC.
Note: The update may take up to 15 minutes. You should therefore only start this process if you have sufficient
time available.
Proceed as follows for updating:
Remove the old MMC.
If the Operating and Monitoring System is accessing the MMC at the moment, the following message appears:
"Storage Card MMC Warning: The system has not finished updating the files in the Storage Card MMC folder. Please
reinsert the storage card now. WARNING: Failure to do so may result in lost data on the storage card.
Replace the (old) MMC that you have just removed and confirm the warning with "OK".
Repeat the removal of the MMC again after waiting a moment.
Insert the new MMC into the slot as shown in the picture. If the MMC is correctly in place, it only projects a few
millimetres out of the slot.
Page 8 of 11

TP10
H024
Version 1 (10/07)
MMC
MMC slot
Figure 7: Inserting the MMC
In the menu bar

call up the system settings
and then the version information
updated from MMC; see Operating Instructions G300, G301, G400 or G401).
Do not do anything until the following message appears:
"INFO: You are starting RESTORE now. All files (except files on storage cards) and the registry will be erased. Are you
sure?"
Answer "Yes". The updated will be started and may take several minutes.
When the Loader appears (see Figure 6), bring up the RESTORE window behind by typing to the front. Do not try to
carry out any actions in the Loader. Do not do anything else until the following message appears:
"RESTORE: Restore of CE Image finished. The device will be rebooted now. Don't remove the storage card."
Answer "OK". The updated will be continued and may take several minutes. Even if the screen goes blank for a while,
do not do anything until the following message appears:
"RESTORE: Restore successfully finished. Press ok, remove your storage card and reboot your device."
Answer "OK", but do not remove the MMC; leave it in the device.
Even if the screen goes blank for a while, do not do anything until the main screen appears (see Operating Instructions
G300, G301, G400 or G401). This may take a few minutes.
and select
(load
Result:
The operating update from the MMC is not on the Operating and Monitoring System.
Normal messages during the update process:
"Please wait until runtime has been terminated."
"Starting Restore"
"Checking data"
"Deleting files on flash"
"Restore CE Image"
"Restore data in progress."
"RESTORE in progress: ..."
"Restore registry in progress."
"loading"
A Windows Desk that appears temporarily or in the background is also normal.

Do not try to carry out any actions on this Desktop.
What to do if the update process is interrupted:
"Storage Card MMC Warning: The system has not finished updating the files in the Storage Card MMC folder. Please
reinsert the storage card now. WARNING: Failure to do so may result in lost data on the storage card."
Replace the (old) MMC that you have just removed and confirm the warning with "OK"
Page 9 of 11

TP10
H024
Version 1 (10/07)
Repeat the removal of the MMC again after waiting a moment.
"ABORT RESTORE: Storage card couldn't be detected. Try restore again? Insert storage card and Press 'OK' or abort
restore with 'CANCEL'."
Remove the (new) MMC, replace it and start again with "OK" .
If that does not help, remove the new MMC and select "X" to cancel the update. When the Loader appears
(see Figure 6), press "Start". The old operating program is loaded again. This can also take several minutes.
Insert the old MMC again and ask Loos International for a new MMC.
"Storage Card MMC Warning: Would you like the system to format the Storage Card MMC folder so that the system can
use it? WARNING: If you select Yes, any files in the Storage Card MMC folder will be erased."
"RESTORE: Abort Restore. Remove your storage card."
Always answer this warning with "No"!

Remove the (new) MMC and confirm the message with "OK". Insert the old MMC again once the old operating
program has loaded again.
Answer "No" to: "INFO: You are starting RESTORE now. All files (except files on storage cards) and the registry will be
erased. Are you sure?"
When the Loader appears (see Figure 6), remove the new MMC and press "Start". The old operating program
is loaded again. This can also take several minutes. Insert the old MMC again.
11 Shutting down
When the system is removed, it must be disposed of according to the regional environmental protection regulations in such
a way that this system cannot cause any danger to the environment.

repair:
Observation/Fault:
Operator panel not working properly
Cause
Repair
Bus connection to CPU faulty
Check bus connection
Incorrect planning
Replace system
By whom?

The Operating and Monitoring System is designed to be low-maintenance. However, you should clean the Touch Screen
regularly.
Attention! Error!
Only clean the Operating and Monitoring System when it is switched off or, in the menu bar
call up system
and then Clean Touch Panel

(see Operating Instructions G300, G301, G400 or G401). In
settings
this way, you can make sure that you do not accidentally trigger any functions when cleaning.
To clean the panel, only use a damp cleaning cloth with a detergent or screen-cleaning foam. Never use aggressive
solvents or harsh cleaning products.
Page 10 of 11

TP10
H024
Version 1 (10/07)
Spray the cleaning product onto the cleaning cloth. Do not spray it directly onto the Operating and Monitoring System.
When cleaning, wipe from the edge of the screen inwards.
The Operating and Monitoring System cannot be repaired in situ. If it is found that the system is faulty, it must be replaced
with a new one. The system that has been removed must be sent back to Loos International.
The Operating and Monitoring System may only be replaced by a qualified electrician who is familiar with the
relevant skills in installing electronic components, especially stored-program control devices.
Touch panel Simatic MP277 10", TFT-Colour:
Material number 10026611
All hardware illustrations:

Copyright Siemens AG, Germany
Page 11 of 11
Central Processing Unit

CPU 313C
H026
Version 1 (11/07)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Construction................................................................................................................................................................. 2
6.2
CPU front side ............................................................................................................................................................. 3
6.2.1
Status and fault display................................................................................................................................................ 3
6.2.2
Memory card................................................................................................................................................................ 3
6.2.3
Operating mode switch ................................................................................................................................................ 4
6.3
Integrated peripheral equipment .................................................................................................................................. 4
6.4
Optional additions ........................................................................................................................................................ 4
Assembly.................................................................................................................................................................... 6
9.1
Exchanging the central processing unit ....................................................................................................................... 6
9.2
9.3
9.3.1
Basic instructions......................................................................................................................................................... 7
9.3.2
Potential equalisation................................................................................................................................................... 8
9.3.3
Earth connection.......................................................................................................................................................... 8
9.3.4
Power supply ............................................................................................................................................................... 8
9.3.5
MPI-Bus ....................................................................................................................................................................... 8
9.3.6
Sensors and actors ...................................................................................................................................................... 9
10
Start-up ....................................................................................................................................................................... 9
10.1
Initial start-up ............................................................................................................................................................. 10
10.2
Application program update ....................................................................................................................................... 10
10.2.1 Update with power supply switched off ...................................................................................................................... 10

10.2.2 Update with power supply switched on ...................................................................................................................... 10
10.3
Master reset with RAM faults ..................................................................................................................................... 11
11
Shutting down.......................................................................................................................................................... 11
12
13
14
Page 1 of 14

CPU 313C
H026
Version 1 (11/07)
The central processing unit delivered by Loos International is exclusively destined for instrumentation and control tasks in
boiler systems within the framework of the LBC Loos boiler control or the LSC Loos system control. It functions together with
further subassemblies, sensors and the control elements. An operation and monitoring system delivered by Loos
International operates and monitors the process (see Operating Instructions H023 / H024).
The central processing unit may only be built into a closed control cabinet and used only within the framework of the
operating conditions described in the chapter on technical data.
Any other operation is not in compliance with the regulations and therefore not permitted.
The MPI interface integrated in the CPU is reserved solely for Loos internal use and may not be used in any other way.
Safety
6
6.1

Construction
CPU
Integrated peripheral
equipment
Figure 1: Central processing unit CPU 313C
Page 2 of 14

CPU 313C
H026
Version 1 (11/07)
The central processing unit CPU 313C consists of the actual CPU and an integrated peripheral equipment of 24 digital and 5
analogue inputs as well as 16 digital and 2 analogue outputs.
Any work at the central processing unit and all parts connected to it may exclusively be carried out by trained
qualified electricians who have adequate technical knowledge of the assembly of electronic subassemblies and
in particular of programmable logic controllers.
6.2
CPU front side

Status and fault display
Memory card ejector
Memory card
Operating mode switch
Front door
MPI interface
Power supply connection
Figure 2: Front side CPU 313C
6.2.1

Note: All LEDs flash for a short period when the CPU starts operating.
LED
Colour
Meaning
SF
Red
System error
DC5V
Green
5V supply for CPU and internal bus exists
FRCE
Yellow
Force order is active, not relevant to applications within the framework for LBC / LSC
RUN
Green
CPU in operation (the LED flashes with 2 Hz when the CPU starts)
STOP
Yellow
The CPU does not operate or is starting to operate (with a request for master reset the
LED flashes with 0.5 Hz; during master reset it flashes with 2 Hz, see chapter 10)
Exact details of certain LED displays are described in chapter 12 Measures in the event of unusual observations and
operating faults.
6.2.2
Memory card
The Loos International memory card contains the application program and the factory settings for your application or the
settings that the Loos customer service stored during commissioning.
In case of a CPU failure these data can be transferred to the new control unit with the card.
Attention! The content of the memory card can become invalid if the card is removed during the writing process.
In that case the card might have to be reformatted. Never remove the memory card in the RUN or CPU
operating mode. It may exclusively be removed when the unit is disconnected from the power supply or in the
STOP state of the CPU.
System and main memory are integrated in the CPU. They serve for processing the application program. The main memory
is a maintenance-free retentive memory, i.e. you do not need any back-up batteries for operation. The main memory content
also remains stored when the power supply is switched off.
Page 3 of 14

CPU 313C
H026
Version 1 (11/07)
6.2.3
The operating mode switch has three positions:

RUN:
The CPU processes the application program (position for normal mode).
STOP: The CPU does not processes any application program (position e.g. for work at the central processing unit like
loading an application program update, see chapter 10)
MRES: CPU master reset position (see chapter 10).
Attention! A master reset causes data losses! Exclusively set the operating mode switch in the MRES position
for operator control actions described in these Operating Instructions.
6.3
Integrated peripheral equipment
3 analogue inputs
8 digital inputs
8 digital inputs
8 digital outputs
LEDs of digital inputs and outputs
8 digital outputs
8 digital inputs
1 analogue input, 2 analogue outputs
Plug:
X11
X12
Observe the graphic symbols on the back of the front doors!
Figure 3: Central processing unit CPU 313C, integrated peripheral equipment

The LEDs of the digital inputs and outputs light up permanently in green when the input / output has been set.
6.4
Optional additions
The central processing unit can be extended by optional components depending on the central processing unit:
Components
Operating
instructions
Signalling modules:
Digital input module SM321
Digital output module SM322
Analogue input module SM331
Analogue output module SM332
H035
H036
H037
H038
Function
Extend the integrated peripheral equipment by

digital and analogue inputs and outputs
Connect the automation system with bus systems
Communication modules:
CP343 for industrial Ethernet
CP342-5 for PROFIBUS DP
H030
H032
Connector units IM360 / IM361
H033
Connect the automation system to an extension

rack that contains additional modules a special
connection cable is necessary for connection
Page 4 of 14

CPU 313C
H026
Version 1 (11/07)
Dimensions:
Width: 120 mm, height: 125 mm, depth: 115 mm (180 mm with open front door)
Installation dimensions:
Width: 120 mm, height: 125 mm, depth: 130 mm
Weight:
660 g
0 ... + 60 C (horizontal mounting)
Relative air humidity during operation:
10 ... 90% without condensation
Air pressure:
1080 ... 795 hPa (corresponds to a height of 1000 to 2000 m)
Supply voltage
Safety-low voltage, SELV
Admissible range:
20.4 VDC ... 28.8 VDC ...
Current consumption (nominal value):
700 mA
Current consumption (typ. in idle

running):
150 mA
Power loss (typ.):
14 W
System of protection:
IP20
Main memory:
64 KByte
Loading memory:
Via memory card, max. 8 MByte
Integrated analogue inputs 4...20 mA:
4 inputs, admissible input current max. 25 mA respectively
Integrated digital inputs:
24 inputs, max. input voltage 30 V respectively, typ. input voltage 9 mA
Integrated analogue outputs 4...20 mA:
2 outputs, max. working resistance 300
Integrated digital outputs:
16 outputs, nominal load voltage 24 V, nominal load current 0.5 A
MPI interface:
RS485 (15...30 VDC, max. 200 mA; max. 187.5 kBaud)
Nominal value (UN): 24 VDC
The central processing unit is packaged with sufficient protection by the factory. Pay attention that the central processing
unit is transported and stored in a dry way and that the admissible ambient conditions are not exceeded or fallen short of
during transport and storage.
Type of condition
Admissible range
Free fall (in dispatch packaging): Max. 1 m

Temperature:
40 C to + 70 C
Air pressure:
1080 to 660 hPa (corresponds to a height of 1000 to 3500 m)
Page 5 of 14

CPU 313C
H026
Version 1 (11/07)
Type of condition
Admissible range
Relative air humidity:
10 to 95%, without condensation
Sinusoidal vibrations acc. to IEC

60068-2-6:
5 9 Hz: 3.5 mm, 9 150 Hz: 9.8 m/s
Impact acc. to IEC 60068-2-29:
250 m/s, 6 ms, 1000 impacts
Note: Pay attention that no humidity deposits at or in the system (condensation) after transporting the central
processing unit at low temperatures or after extreme temperature fluctuations.
Adjust the central processing unit to the room temperature before commissioning. Do not expose the CPU to
direct radiation of a heating unit. When thawing the unit, wait until it has dried completely and do not switch it on
before a waiting period of approx. 4 hours has expired.
Assembly
9.1
Exchanging the central processing unit
The central processing unit cannot be repaired on site. If the central processing unit is discovered to be defective, it should
be replaced by a new one. The disassembled unit must be sent to Loos International.
Mechanical and electrical assembly is described in the following sections.
Disassembly takes place in the reverse order to assembly.
9.2
Danger: Risk of fatal injury through electric current! The central processing unit should never be assembled or
In addition to this the central subassembly may be completely destroyed.
Attention! The central processing unit and any further necessary subassemblies are open electrical equipment.
The subassemblies may only be installed in a closed control cabinet. Only instructed and authorized personnel
should be allowed access.
Ensure that the power supply to the control cabinet is switched off completely before starting the assembly work.
Use a horizontally mounted 122 mm profile rail as a mounting rack. The rail must be so positioned that enough room
remains for the assembly and heat dispersal of the subassemblies (at least 40 mm above and below the
subassemblies).
The central processing unit and any further necessary subassemblies can be mounted on the profile rail (a maximum of
8 further subassemblies; the central subassembly should always be on the left, where necessary the electric power
supply to the left of the central subassembly).
If applicable, insert the bus connectors into the central processing unit and the other subassemblies. Begin
with the central processing unit. For this, use the bus connector included with the subassembly which is to be
assembled on the far right. No bus connector is inserted into the subassembly on the far right.
Mount the subassemblies in the designated order (1), push each subassembly into the previously mounted
subassembly (2) and swivel the subassembly downwards (3).
Page 6 of 14

CPU 313C
H026
Version 1 (11/07)
Screw down the subassemblies.
Figure 4: Attach bus connector
9.3
Hang up subassemblies
Screw down subassemblies
Prerequisites:
The central processing unit and any further necessary subassemblies have been mounted according to the
specifications of the present operating instructions.
The power supply for 24 VDC has been installed (according to the technical data in chapter 7).
9.3.1
Basic instructions
Ensure that the power supply to the control cabinet is switched off completely before starting to work!
Ensure that any hitherto existing wiring has been laid according to the recognised rules and valid standards of electrical
engineering.
The prevailing national and regional specifications must be strictly adhered to during installation. Enquiries should be
made to the local authorities about these specifications and requirements if necessary.
The cables used must have dimensions in accordance with the recognised rules of electrical engineering, so that an
adequate power supply is guaranteed. It must always be ensured that the heating up of the wiring is within permitted
limits.
The cable cross section of all signal lines must be so laid that the signal flow is always in the necessary amplitude.
All cables must be laid in such a way that wiring routes are as short as possible within the framework of the prevailing
specifications.
Mains supply lines must be laid according to the recognised specifications of electronic and electrical engineering.
Always screw connections down sufficiently.
A single circuit breaker disconnecting the power supply to the central processing unit as well as to all input and output
circuits is imperative.
Connected control elements must be fitted with approved and adequately dimensioned protective circuits according to
the respective manufacturers instructions. If such instructions are not available, the protective circuits must be fitted
according to the recognised specifications of electrical engineering.
Always use sheathed wiring for measuring lines. Ensure that the sheathing is connected to the potential equalisation of
the measuring equipment. A connection of the sheathing at both ends should be avoided if possible.
The connections of digital and analogue inputs and outputs must be carried out in accordance with the order-related
wiring diagram of the respective control cabinet.
Observe the maximum voltage and current values for all inputs and outputs.
Page 7 of 14

CPU 313C
H026
Version 1 (11/07)
Caution! The maximum load for 4...20 mA signal analogue inputs must not exceed 25 mA. On no account may
testing equipment without appropriate current limitation be used to test the inputs.
Caution! Incorrect connection of transducers can lead to the destruction of analogue inputs (observe the
transducer wiring diagram and documentation!)
9.3.2
Potential equalisation
It is possible that potential differences occur between parts of the plant located at different locations. Potential differences
can also be caused by different network supplies. The potential differences can cause high equalising currents via data
cables which might bring about destruction of the interfaces. Equalising currents can particularly occur when cable shields
are installed on both sides and earthed at different parts of the plant.
Potential differences must be reduced by laying potential equalising cables until the electronic components function
faultlessly.
Observe the following for the installation of the potential equalisation:
The wider the cross section of the potential equalising cable, the higher the effect of the potential equalisation.
The cross section of a potential equalisation cable must be dimensioned for the max. flow of equalising current.
Between switchgear cabinets, potential equalisation cables with a min. diameter of 16 mm have proven to be useful in
practice.
Use potential equalisation cables made of copper or galvanised steel.
Connect the potential equalisation cables to the earth/protective conductor with a large area of contact to protect the
connection against corrosion.
Lay the potential equalisation and data cables parallel with a minimum distance to each other.
Cable shields are not suitable for potential equalisation!
9.3.3
Earth connection
Connect the profile rail to the protective conductor. There is an M6 protective conductor screw for this on the far left of the
rail. Ensure there is a large area of contact. Minimum cross section of the protective conductor: 10 mm.
9.3.4
Power supply
Connect the power supply as follows
Open the front door of the CPU (see Figure 2).
Connect contact M (earth) of the power supply to the M contact of the CPU, and the contact L+ of the power supply (24
volt supply) to the L+ contact of the CPU. Reversing the polarity of contacts M and L+ sets off the CPU internal safety
device.
Close the front door of the CPU again.
9.3.5
MPI-Bus
Within the framework of the LBC Loos Boiler Control or the LSC Loos System Control, the MPI bus is generally used for the
connection of a TP6 / TP10 operating and monitoring system (see Operating Instructions H023 / H024) and for the
connection of C7-633 automation equipment (see Operating Instructions H018).
All connections via the MPI bus must be carried out according to the order-related wiring diagram of the respective control
cabinet. Particular care should be taken to ensure that the plugs have the correct terminating impedance. For one bus cable
in an MPI plug, the slide switch in the plug should be in the ON position; for two bus cables in the MPI plug the slide switch
should be in the OFF position.
Connect the MPI bus as follows:
Open the front door of the CPU (see Figure 2).
Insert the MPI bus plug into the MPI interface.
Close the front door of the CPU again.
Page 8 of 14

CPU 313C
H026
Version 1 (11/07)
9.3.6
Sensors and actors
Sensors and actuators are connected to the integrated peripheral equipment by means of supplied front plugs. See
Operating Instructions H035 to H038 for the connection to any existing additional signal subassemblies.
Connection of the sensors and actuators should be carried out in accordance with the order-related wiring diagram of
the respective control cabinet.
Open the appropriate front door of the integrated peripheral equipment.
Push the front plug into the subassembly until it locks into place. In this position the plug still protrudes out of the
subassembly and has no electrical contact to the subassembly (wiring position).
The front plugs for the integrated peripheral equipment of the central processing CPU 31 3C unit have spring clips. To
connect up the wiring, insert a 3.5 mm screwdriver vertically into the opening with the red opening mechanism (do not
turn or twist the screwdriver!), insert the wire into the clip and then remove the screwdriver.
When you have connected all sensors and actuators, lay the supplied strain relief around the wiring and the front plug
and pull the strain relief tight.
Screw down the fastening screw in the centre of the front plug. By doing this you pull the connector towards the
subassembly, and electrical contact is made.
The codification in the front plug locks in. The plug now fits only to subassemblies of the same type.
Close the front door of the integrated peripheral equipment.
Figure 5: Open the front door, insert the front plug, connect the wiring, screw in the front plug, close the front door
Note: If you need to replace the central processing unit, use the already connected front plug of the old
subassembly to connect the sensors and actuators! But you must remove the upper part of the front plug
codification from the new subassembly, as this part already exists in the connected front plug.
10 Start-up
Preconditions for commissioning:

Assembly and electrical connection of the central processing unit have been carried out in accordance with the
specifications of these Operating Instructions. The power supply for the central processing unit has not been switched on
yet.
Page 9 of 14

CPU 313C
H026
Version 1 (11/07)
The application program is on a memory card which is part of the Loos International delivery.
If this memory card is not located in the central processing unit yet, insert the memory card into the central processing
unit in such a way that the chamfered corner faces the card holder / ejector (downwards). Push the card in until the
holder behind the card locks into place.
Figure 6: Inserting the memory card
Set the operating mode switch of the CPU on STOP (see Figure 2 and 6.2.3).
Switch on the power supply for the CPU.
The green LED DC5V on the CPU lights up permanently.
After a short waiting period, the yellow STOP LED will flash with 2 Hz, while the CPU carries out the automatic master
reset.
After master reset, the yellow STOP LED will light up permanently.
Set the operating mode switch of the CPU at RUN (see Figure 2 and chapter 6.2.3).
Check the function of the control unit according to the order-related documents.
If any problems occur contact Loos International immediately.

Note: If you have to replace the central processing unit you can insert the old memory card with the previous
application program into the new central processing unit. If the memory card is defective, too, request a backup
copy at Loos International.
10.2 Application program update

You will receive updates of the application program from Loos International on a memory card.
Note: All important plant-specific parameters must be documented before loading a program update. After
loading, these plant-specific parameters might have to be entered manually if the existing parameters have not
been taken over completely.
10.2.1 Update with power supply switched off
Press the ejector on the memory card opening with a ballpoint pen or small screwdriver (see Figure 2)
Remove the old memory card.
Continue as described in chapter 10.1 Initial start-up)
10.2.2 Update with power supply switched on
Set the operating mode switch of the CPU on STOP (see Figure 2 and chapter 6.2.3).
Ensure that no recording functions are running on the programming equipment. In case of doubt remove the MPI plug.
Press the ejector on the memory card opening with a ballpoint pen or small screwdriver (see Figure 2)
Remove the old memory card.
Page 10 of 14

CPU 313C
H026
Version 1 (11/07)
Insert the new memory card into the central processing unit in such a way that the chamfered corner faces the
cardholder/ ejector (downwards), (see figure 6). Push the card in until the holder behind the card locks into place.
Perform the master reset.
Press the operating mode switch into the MRES position (see figure 2 and 6.2.3).
Keep the switch in this position until the STOP LED lights up for the second time (after about 3 seconds).
Release the switch.
Within 3 seconds press the operating mode switch back into the MRES position.
Keep the switch in this position until the STOP LED flashes at 2 Hz.
Release the switch.
The CPU performs the master reset.
The master reset is complete when the STOP LED stops flashing and lights up permanently.
Set the operating mode switch of the CPU on RUN (see figure 2 and chapter 6.2.3).
Check the control function.
If any problems occur contact Loos International immediately.
10.3 Master reset with RAM faults

If there is a RAM fault the CPU independently requests a master reset by a flashing of the STOP LED at 0.5 Hz. In this case
push the operating mode switch briefly into the MRES position (see figure 2 and chapter 6.2.3) This starts the master reset.
11 Shutting down
When the system is removed, it must be disposed of according to the regional environmental protection regulations in such
a way that this system cannot cause any danger to the environment.

repair:
Observation/Fault:
The SF (system error) status LED lights up in red
Cause
Repair
Electrical faults
The switchboard must be earthed sufficiently and

according to the instructions.
By whom?
Avoid parallel laying of high and low voltage lines.

Check transmission within the wiring inside the
cabinet.
Earth the M terminal of the 24 V/DC supply voltage
Check DC supply voltage, exchange device
Switch off power supply, wait for 30 seconds and
switch on again
Internal CPU or peripheral equipment fault
Replace device
Page 11 of 14

CPU 313C
H026
Version 1 (11/07)
Observation/fault:
The status-LED DC5V (5 V d.c. power supply) is not illuminated
Cause
Repair
Internal DC 5 V supply has failed
Replace device
Observation/fault:
The status-LED RUN (operating state) is flashing green (2 Hz)
Cause
Repair
If the status LED STOP is illuminated yellow, the

central subassembly is starting up. After the STOP
display has gone out, the outputs are released.
No action necessary
Observation/fault:
Repair
Force application active, not relevant
No action necessary
Repair
Operating mode switch in STOP position
Set operating mode switch in RUN position
By whom?
The STOP (operating state) status LED lights up in yellow (0.5 Hz)
Cause
Repair
Central processing unit requests master reset
See chapter 10.3 Master reset with RAM faults
Observation/Fault:
By whom?
The STOP (operating state) status LED lights up in yellow
Cause
Observation/Fault:
By whom?
The status LED FRCE (force applied) is illuminated yellow
Cause
Observation/Fault:
By whom?
By whom?
Status LEDs of a digital input/output lights up green although the corresponding

connection is not set
Cause
Repair
Input/output faulty
Replace subassembly
By whom?
Page 12 of 14

CPU 313C
H026
Version 1 (11/07)
Observation/Fault:
Status LEDs of a digital input/output does not light up green although the
corresponding connection is set
Cause
Repair
Input/output faulty
Replace subassembly
Observation/Fault:
By whom?
The outputs no longer function
Cause
Repair
In the device which is being controlled an electrical

overload has occurred, causing damage to the
output.
Whilst connecting to inductive loads (e.g. relays)

proper protective switches must be fitted.
Overload
Check load against nominal value of outputs

(max.0.3 A).
Loose or defective wiring
Check wiring with the wiring diagram
CPU in STOP (yellow STOP LED lights up)
Move operating mode switch to RUN position.
Fault in the application program
Correct the application program.
By whom?

The central processing unit is a maintenance-free system. It cannot be repaired on site. If the central processing unit is
discovered to be defective, it should be replaced by a new one. The disassembled subassembly must be sent to Loos
International.
Page 13 of 14

CPU 313C
H026
Version 1 (11/07)
Central processing unit CPU 313C: Identity number 10026603
Illustrations partly Copyright by Siemens AG, Germany
Page 14 of 14
Communication Module
CP343-1 Lean Industrial Ethernet
To connect Loos Boiler Control LBC and Loos System Control LSC
H030
Version 2 (10/09)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Construction ................................................................................................................................................................. 2
6.2
Status and fault display ................................................................................................................................................ 2
Assembly .................................................................................................................................................................... 4
9.1
Replacing subassemblies............................................................................................................................................. 4
9.2
Mechanical installation ................................................................................................................................................. 5
9.3
Electrical installation..................................................................................................................................................... 5
9.3.1
Power supply................................................................................................................................................................ 5
9.3.2
Industrial Ethernet ........................................................................................................................................................ 6
10
Start-up ....................................................................................................................................................................... 6
11
Shutting down ............................................................................................................................................................ 6
12
13
14
The CP343-1 Lean module supplied by Loos International facilitates communication between LBC and LSC (see Operating
Instructions G300 / G301 / G400 / G401) via Industrial Ethernet. It is the exclusive purpose of the module to fulfil tasks in
boiler systems within the scope of the application programmes uploaded into the central unit of LBC and LSC by Loos
International.
Page 1 of 9
H030
Version 2 (10/09)
Safety
6
6.1

Construction
Front door
Figure 1: CP343-1 Lean communication module

Any work at the communication module and all parts connected to it may exclusively be carried out by trained
6.2

Note: All LEDs may flash for a short period when the communication module starts operating.
LED
Colou Meaning
r
LED
Colour
Meaning
SF
Red
System error
RUN
Green
Communication module is running
BF
Red
Bus fault (e.g.: no cable, double IP address
STOP
Yellow
Communication module stopped
Page 2 of 9
H030
Version 2 (10/09)
detected)
DC5V
Green 5 VDC voltage supply available via back

plane bus
RX/TX Green Flashes when module is sending/receiving

via Industrial Ethernet
P1
Green/
yellow
Ethernet port 1 connection status
P2
Green/
yellow
Ethernet port 2 connection status
Meaning of the connection status LED displays ( = LED flashes, z = LED is illuminated, | = LED is not illuminated):
P1 / P2
Meaning
Ethernet port is not connected to Industrial Ethernet
z Green
Ethernet port is connected to Industrial Ethernet
Ethernet port is sending/receiving via Industrial Ethernet or Profinet IO
z Yellow
Ethernet port is continuously sending/receiving via Industrial Ethernet or Profinet IO
Meaning of the special combinations of LED displays ( = LED flashes, z = LED is illuminated, | = LED is not illuminated):
SF (red)
BF (red)
RUN
(green)
STOP
(yellow)
Meaning
Module fault
z/|
Communication module stopped with fault, also:

communication module runs after supply voltage connection
Communication module starts
Communication module stops
Dimensions:
Weight:
Approx. 220 g
Air pressure:
Supply voltage:
Admissible range:
20.4 VDC ... 28.8 VDC
Current consumption from 24V supply max.:
Approx. 200mA
Current consumption from back wall bus

max.:
200 mA
Power dissipation
Approx. 5.8 W
Page 3 of 9
H030
Version 2 (10/09)
IP20
Transmission speed:
10 Mbit/s and 100 Mbit/s
The subassembly has been packaged with sufficient protection by the factory. Pay attention that the subassemblies are
transported and stored in a dry way and that the admissible ambient conditions are not exceeded or fallen short of during
transport and storage.
Type of condition
Admissible range

Temperature:
40 C to + 70 C
Air pressure:

60068-2-6:
5 9 Hz: 3.5 mm, 9 150 Hz: 9.8 m/s
Assembly
Any work at the module and all parts connected to it may exclusively be carried out by trained qualified
electricians who have adequate technical knowledge of the assembly of electronic subassemblies and in
particular of programmable logic controllers.
9.1
Replacing subassemblies
The subassembly cannot be repaired on site. If the subassembly is discovered to be defective, it should be replaced by a
new one. The disassembled subassembly must be sent to Loos International.
Page 4 of 9
H030
Version 2 (10/09)
9.2
Attention! The subassemblies are open electrical equipment. They may only be installed in a closed control
cabinet. Only instructed and authorized personnel should be allowed access.
Read the Operating Instruction on the central processing unit (H026/H027/H028) for mechanical installation.
Mount the subassemblies on a 122 mm profile rail as described in the operating instructions on the central processing
unit. The rail must be so positioned that enough room remains for the assembly and heat dispersal of the
subassemblies (at least 40 mm above and below the subassemblies).
9.3
Note: Observe the chapters Basic Instructions and Potential Equalisation in the operating instructions on the
central processing unit (H026 / H027 / H028).
Prerequisites:
The power supply for 24 VDC, the central processing unit and all further subassemblies has been installed in
accordance with the specifications in the respective operating instructions.
The electric connection of the central processing unit has been established in accordance with the specifications in the
relevant operating instructions (see H026/H027/H028) and according to the order-related wiring diagram.
Ethernet port 1 (8-pin RJ-45 socket)

Ethernet port 2 (8-pin RJ-45 socket)
Slider to adjust the mass connection
(Front door opened)
Figure 1: Connections of communications assembly CP343-1 Lean
Note: The slider to adjust the mass connection must be pushed in. The mass and reference earth are then
connected (Use a screwdriver to actuate the slide. The slider noticably locks in place. The slider is pushed in in
the delivered condition.)
9.3.1
Power supply
Note: Communication module and central processing unit (and interface module IM361 if applicable) must be
connected to the same power supply!
Page 5 of 9
H030
Version 2 (10/09)
Connect the power supply as follows:
Open the front door of the communication module (see figure 1).
Connect contact M (earth) of the power supply to M contact of the communication module and contact L+ (24 volt
supply) of the power supply to the L+ contact of the communication module (also see figure 2).
Close the front door of the communication module.
9.3.2
Industrial Ethernet
All the Industrial Ethernet connections shall be made according to the order-related circuit diagram of the corresponding
control cabinet.
Connect the Industrial Ethernet like this:
Open the front door of the communications assembly (see Figure 1).
Connect the RJ-45 connector of the Ethernet cable into Ethernet port 1 (see Figure 2). Connect any other second
Ethernet cable to Ethernet port 2; see the order-related circuit diagram.
Close the front door of the communications assembly again.
Note: Ethernet cables can also be connected and disconnected when the power supply is switched on.
10 Start-up
Prerequisites for commissioning:
The power supply for 24VDC, the central processing unit and all other subassemblies including the communication
module have been installed in accordance with the specifications in the respective operating instructions and electrically
connected in accordance with the order-related wiring diagram of the corresponding control cabinet.
The Industrial Ethernet has been installed in accordance with the order-related wiring diagrams.
Commissioning:
The communication module is commissioned together with the central processing unit.
The project planning data of the communication module are stored on the CPU memory card in a power failure safe way
and loaded into the communication module during the start of the CPU. No special actions are necessary for the
communication module.
Read the Operating Instructions on the central processing unit (H026 / H027 / H028) for commissioning.
11 Shutting down
Disassembled subassemblies must be disposed of in accordance with the respective applicable regulations on
environmental protection in such a way that the subassemblies cannot cause any danger to the environment.
Page 6 of 9
H030
Version 2 (10/09)

repair:
Observation/Fault:
All status LEDs are flashing
Cause
Repair
Module fault

switch on again
By whom?
Replace module
Observation/Fault:
The SF (system error) status LED lights red
If the STOP status LED lights yellow at the same

time, the communication module starts after
connection of the power supply.
No activities required
Electrical faults

cabinet.
switch on again
Internal communication module fault
Observation/Fault:
Replace module
The BUSF (bus error) status LED lights red
Cause
Repair
If the SF status LED lights red and the STOP status

LED lights yellow at the same time, the
communication module starts after connection of
the power supply.
No Ethernet cable connected
Check if the RJ-45 plug has been inserted properly

in the Ethernet port, check Ethernet cable
Double IP address detected
Check IP addresses
By whom?
Page 7 of 9
H030
Version 2 (10/09)
Observation/fault:
The status-LED DC5V (5 V d.c. power supply) is not illuminated
Cause
Repair
Internal DC 5 V supply has failed
Replace device
Observation/Fault:
The RUN status LED (operating state) flashes green
Cause
Repair

time, the communication module is starting.
Observation/Fault:
By whom?
By whom?
The STOP status LED (operating state) flashes yellow
Cause
Repair
If the RUN status LED lights green at the same

time, the communication module is stopping.
By whom?

The subassemblies are maintenance-free systems. They cannot be repaired on site. If a subassembly is discovered to be
defective, it should be replaced by a new one. The disassembled subassembly must be sent to Loos International.
CP343-1 Lean communication module:
Identity number 10026609
Page 8 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Construction................................................................................................................................................................. 2
6.2
Status and fault display................................................................................................................................................ 3
6.3
Operating mode switch ................................................................................................................................................ 3
Assembly.................................................................................................................................................................... 5
9.1
Replacing subassemblies ............................................................................................................................................ 5
9.2
9.3
9.3.1
Power supply ............................................................................................................................................................... 5
9.3.2
Profibus........................................................................................................................................................................ 6
10
Start-up ....................................................................................................................................................................... 6
11
Shutting down............................................................................................................................................................ 7
12
13
14
Page 1 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
The communications module supplied by Loos International facilitates the connection between LBC and LSC (see Operating
Instructions G300 / G301 / G400 / G401) to a Profibus system, for example, to communicate with a Central Instrumentation
and Control (CIC) or with Loos Water Analyser (LWA). It is the exclusive purpose of the module to fulfil tasks in boiler
systems within the scope of the application programmes uploaded into the central unit of LBC and LSC by Loos
International.
The communication module may only be built into a closed control cabinet and used only within the framework of the
Safety
6
6.1

Construction
9-pin sub-D connector for Profibus connection


Front door
Figure 1: Communication module CP342-5
Page 2 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
Any work at the communication module and all parts connected to it may exclusively be carried out by trained
6.2

Note: All LEDs may flash for a short period when the communication module starts operating.
LED
Colour
Meaning
SF
Red
System error
BUSF
Red
Bus error
RUN
Green
Communication module is running
STOP
Yellow
Communication module stopped
Meaning of the special combinations of LED displays ( = LED flashes, z = LED is illuminated, | = LED is not illuminated):
SF (red)
BUSF (red)
RUN
(green)
STOP
(yellow)
Meaning
Module fault
If communication module is DP master: Communication module

is running, data exchange with at least one DP slave (e.g. LWA
module) is disturbed.
If communication module is DP slave: Communication module is
running, parameterisation of communication module by DP
master (e.g. ZLT) has not been completed successfully yet.
Communication module starts
Communication module stops
6.3
The operating mode switch has two positions:

RUN:
Position for normal mode
STOP: Position for project planning and diagnosis

When the system switches from STOP to RUN, the communication module transfers the necessary data to the main
memory and starts running.
When the system switches from RUN to STOP, the communication module interrupts all connections and stops.
Page 3 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
Dimensions:
Weight:
Approx. 300 g
Air pressure:
Supply voltage:
Current consumption from 24V supply typ.:
250 mA
Current consumption from back wall bus

typ.:
150 mA
Power dissipation
6W
Current consumption of network

components at the Profibus interface:
Max. 100 mA with 5V
IP20
Supported communication services:
Profibus DP master class 1 / class 2, alternatively Profibus DP slave
Transmission speed:
See Technical Information TI034
Type of condition
Admissible range

Temperature:
40 C to + 70 C
Air pressure:

60068-2-6:
5 9 Hz: 3.5 mm, 9 150 Hz: 9.8 m/s
Page 4 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
Assembly
9.1
9.2
Read the Operating Instruction on the central processing unit (H026/H027) for mechanical installation.
9.3
central processing unit (H026 / H027).
Prerequisites:
relevant operating instructions (see H026/H027) and according to the order-related wiring diagram.
9.3.1
Power supply
Note: Communication module and central processing unit (and interface module IM361 if applicable) must be
connected to the same power supply!
Connect the power supply as follows:
Page 5 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
Connect contact M (earth) of the power supply to M contact of the communication module and contact L+ (24 volt
supply) of the power supply to the L+ contact of the communication module (also see figure 2).
Connect the connection
9.3.2
of the communication module with the protective earth conductor.
Profibus
All Profibus connections must be installed according to the order-related wiring diagram of the respective control cabinet.
If you have to wire a Profibus connector, please observe
that the cores must always be connected at the same connection (e.g. always connect green core to connection A, red
cores to connection B), and
that the cable shield lays bare on the shield contact surfaces.
Pay attention that the terminators in the connectors are correctly adjusted:
At the start and the end of a segment the slide switch of the plug must be set to the ON position (bus cable ends in
connector, only one cable comes out of connector).
In all other cases (bus cable passing through the connector, two cables come out of connector) the slide switch must be
set to the OFF position.
Note: Stations with connected terminators must always be supplied with power during start and operation;
otherwise the terminator has no effect and the data traffic on the bus could be disturbed.
However, Profibus connectors with bus cable passing through can be pulled off an interface any time without interrupting the
data traffic on the rest of the bus.
Connect the Profibus as follows:
Plug the wired Profibus connector on the 9-PIN Sub-D connector (see figure 1).
Screw down the connector.
10 Start-up
The power supply for 24VDC, the central processing unit and all other subassemblies including the communication
module have been installed in accordance with the specifications in the respective operating instructions and electrically
connected in accordance with the order-related wiring diagram of the corresponding control cabinet.
The Profibus-DP network has been installed in accordance with the order-related wiring diagrams.
Commissioning:
Set the operating mode switch of the communication module at RUN.
Otherwise the communication module is commissioned together with the central processing unit.
Page 6 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
The project planning data of the communication module are stored on the CPU memory card in a power failure
safe way and loaded into the communication module during the start of the CPU. No special actions are
necessary for the communication module.
Read the Operating Instructions on the central processing unit (H026 / H027) for commissioning.
11 Shutting down

repair:
Observation/Fault:
All status LEDs are flashing
Cause
Repair
Module fault

switch on again
By whom?
Replace module
Observation/Fault:
The SF (system error) status LED lights red
Electrical faults

cabinet.
switch on again
Internal communication module fault
Observation/Fault:
Replace module
The BUSF (bus error) status LED flashes red
Cause
Repair
If communication module is DP master:

Data exchange with at least one DP slave (e.g.
LWA module) is disturbed.
Check Profibus DP slave (e.g. LWA)
If communication module is DP slave:

Parameterisation of communication module by DP
master (e.g. ZLT) has not been completed
Wait until DP master (e.g. ZLT) has parameterised

DP slave.
By whom?
Page 7 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
Cause
Repair
successfully yet.
Observation/Fault:
By whom?
Check Profibus DP master (e.g. ZLT)
The BUSF (bus error) status LED lights red
Cause
Repair
Profibus fault
Check Profibus cable
By whom?
Check Profibus connector

Check terminator adjustment, connection of the
cores, cable shield connection
Observation/Fault:
The RUN status LED (operating state) flashes green
Cause
Repair

time, the communication module is starting.
Observation/Fault:
The STOP (operating state) status LED lights up in yellow
Cause
Repair
Operating mode switch in STOP position
Set operating mode switch in RUN position
Observation/Fault:
By whom?
By whom?
The STOP status LED (operating state) flashes yellow
Cause
Repair
If the RUN status LED lights green at the same

time, the communication module is stopping.
By whom?

Page 8 of 9
CP342-5 Profibus DP
H032
Version 1 (07/08)
CP342-5 communication module:
Identity number 012248.1
Illustrations partly
Copyright by Siemens AG, Germany
Page 9 of 9

SM331
H037
Version 1 (12/07)
Contents
1
Safety .......................................................................................................................................................................... 1
Assembly.................................................................................................................................................................... 3
9.1
9.2
9.3
Measurement range modules ...................................................................................................................................... 4
9.4
9.4.1
Procedure for 40-pin front plug .................................................................................................................................... 5
9.4.2
Procedure for 20-pin front plug .................................................................................................................................... 5
10
Start-up ....................................................................................................................................................................... 6
11
Shutting down............................................................................................................................................................ 6
12
13
14
The analogue input module delivered by Loos International is exclusively destined for functions in boiler systems within the
framework of application programs of the central processing unit of Loos International.
The analogue input module may only be built into a closed control cabinet and used only within the framework of the
Safety
Page 1 of 7

SM331
H037
Version 1 (12/07)
Figure 1: Analogue input module SM331

The analogue input module SM 331 facilitates the processing of (additional) analogue process signals by the automation
system. The subassembly which is normally used is designed with a 40-pin front plug (see chapter 9.4.1). In some cases,
variants with a 20-pin front plug are used (see chapter 9.4.2). These variants have a red LED for collective fault display and
measurement range modules (see chapter 9.3).
The rating plate is located laterally at the subassembly.

Dimensions:
Weight:
Approx. 250 g
Relative air humidity during operation: 10 ... 95 % without condensation

Air pressure:
Number of input channels:
8 via 40-pin front plug (variant A: 8 via 20-pin front plug (variant B: 2 via 20-pin front
plug)
Current consumption from backplane

bus:
Max. 90 mA (variant A and B: max. 50 mA)
Power loss of the subassembly:
Typ. 0.4 W (variant A: typ. 1 W (variant B: typ. 1.3 W)
Page 2 of 7

SM331
H037
Version 1 (12/07)
IP20
Max. cable length:
Shielded: 200 m
Admissible potential difference
Between the inputs: 2.0 VDC
Admissible input current:
Max. 25 mA per input
Type of condition
Admissible range

Temperature:
40 C to + 70 C
Air pressure:

60068-2-6:
5 9 Hz: 3.5 mm, 9 150 Hz: 9.8 m/s
Assembly
Any work at the subassemblies and all parts connected to them may exclusively be carried out by trained
9.1

Page 3 of 7

SM331
H037
Version 1 (12/07)
9.2
In some cases, the variants of the subassembly have one or several measurement range modules. As these modules
are located on the side of the subassembly, you must check the position of the modules before mounting the
subassemblies (see chapter 9.3).
9.3
Measurement range modules
Before mounting an analogue input module with one or several measurement range modules check if the modules are set at
position C (4 wire current transducer 220mA).
The C on the module must be located next to the b on the subassembly.
If you have to change the position of a measurement range module, proceed as follows:
Remove the measurement range module from the subassembly with a screwdriver.
Turn the module and reinsert it in position C (C on the module next to the b on the subassembly).
Figure 2: Remove measurement range module from subassembly, turn and reinsert in position C
Attention! If the measurement range modules are not in position C, connecting 4 wire current transducers
(420mA) could destroy the subassembly.
9.4
Page 4 of 7

SM331
H037
Version 1 (12/07)
Prerequisites:
The field devices are connected to the analogue input module via the front plug which is part of the delivery.
9.4.1
Procedure for 40-pin front plug
Open the front door of the subassembly.
Wire the subassembly according to the order-related wiring diagram of the associated control cabinet.
Also screw down the screws of the terminals that are not wired.
When you have connected all field devices, lay the supplied strain relief around the cable bundle and the front plug and
pull the strain relief tight.
Close the front door of the subassembly.
Note: If you need to replace the subassembly, use the already connected front plug of the old subassembly to
connect the field devices! But you must remove the upper part of the front plug codification from the new
subassembly, as this part already exists in the connected front plug.
9.4.2
Procedure for 20-pin front plug
Insert the enclosed strain relief for the cable bundle into the front plug.
Wire the subassembly according to the order-related wiring diagram of the associated control cabinet. Also screw down
the screws of the terminals that are not wired.
Tighten the strain relief around the cable bundle.
Press the unlocking button on the upper side of the subassembly and push the front plug on the subassembly while
keeping the unlocking button pressed. Once the front plug is in the correct position the locking button will return to its
original position.
Page 5 of 7

SM331
H037
Version 1 (12/07)
The electrical contact is established.
Figure 4: Open front door, insert front plug, insert strain relief, wire, press unlocking button, insert front plug, close
front door
10 Start-up

The power supply for 24 VDC, the central processing unit and all further subassemblies has been installed in accordance
with the specifications in the respective operating instructions and electrically connected in accordance with the orderrelated wiring diagram of the corresponding control cabinet.
Commissioning:
The digital input module SM331 is commissioned together with the central processing unit. Any special actions for the
subassembly are not necessary. Read the operating instructions on the central processing unit (H026/H027) for
commissioning.
11 Shutting down

repair:
Page 6 of 7

SM331
H037
Version 1 (12/07)
Observation/Fault:
The status LED SF (system fault) is illuminated red (only certain variants of the
subassembly)
Cause
Repair
No power supply to subassembly
Provide supply to L+
By whom?

Analogue input module SM331,
8 inputs, 40-pin front plug:Identity number 10026607

8 inputs, 20-pin front plug:Identity number 012245.1
2 inputs, 20-pin front plug:Identity number 012246.1
Page 7 of 7
Analogue Output Module

SM332
H038
Version 1 (12/07)
Contents
1
Safety .......................................................................................................................................................................... 1
Assembly.................................................................................................................................................................... 3
9.1
9.2
9.3
10
Start-up ....................................................................................................................................................................... 5
11
Shutting down............................................................................................................................................................ 5
12
13
14
The analogue input-/output module delivered by Loos International is exclusively destined for functions in boiler systems
within the framework of application programs of the central processing unit of Loos International.
The analogue input-/output module may only be built into a closed control cabinet and used only within the framework of the
Safety

Page 1 of 6

SM332
H038
Version 1 (12/07)
Figure 1: Analogue output module SM332

The analogue output module SM322 facilitates the output of (additional) analogue signals to the field devices by the
automation system. The subassembly has a red LED for collective fault display.
The rating plate is located laterally at the subassembly.

Dimensions:
Weight:
Approx. 220 g
Relative air humidity during operation: 10 ... 95 % without condensation

Air pressure:
Number of output channels:
4 via 20-pin front plug
Current consumption
-
from backplane bus:
Max. 60 mA
from load voltage L + (without

load):
Max. 240 mA
Power loss of the subassembly:
Typ. 3 W
IP20
Max. cable length:
Shielded: 200 m
Load nominal voltage L+:
24 VDC
Page 2 of 6

SM332
H038
Version 1 (12/07)
Load resistor
Max. 500
Inductive load
Max. 10 mH
Type of condition
Admissible range

Temperature:
40 C to + 70 C
Air pressure:

60068-2-6:
5 9 Hz: 3.5 mm, 9 150 Hz: 9.8 m/s
Assembly
9.1
Page 3 of 6

SM332
H038
Version 1 (12/07)
9.2
9.3
Prerequisites:
The field devices are connected to the analogue input module via the front plug which is part of the delivery.
Wire the subassembly according to the order-related wiring diagram of the associated control cabinet.
Also screw down the screws of the terminals that are not wired.
When you have connected all field devices, lay the supplied strain relief around the cable bundle and the front plug and
pull the strain relief tight.
Page 4 of 6

SM332
H038
Version 1 (12/07)
10 Start-up

The power supply for 24 VDC, the central processing unit and all further subassemblies has been installed in accordance
with the specifications in the respective operating instructions and electrically connected in accordance with the orderrelated wiring diagram of the corresponding control cabinet.
Commissioning:
The analogue output module SM332 is commissioned together with the central processing unit. Any special actions for the
subassembly are not necessary. Read the operating instructions on the central processing unit (H026/H027) for
commissioning.
11 Shutting down
Page 5 of 6

SM332
H038
Version 1 (12/07)

repair:
Observation/Fault:
The status LED SF (system fault) is illuminated red (only certain variants of the
subassembly)
Cause
Repair
No power supply to subassembly
Provide supply to L+
By whom?

Analogue output module SM332:
Identity number 013772.1
Page 6 of 6
MEASURING TRANSDUCERS FOR DIRECT CURRENT AND DIRECT

VOLTAGE
IgT-MU / UgT-MU
Application
The measuring transducers IgT-MU and UgT-MU serve to convert and isolate a direct current or a direct voltage
into a load-independent direct-current and direct-voltage signal. The calibrated double-outputs can be
switched over between 0-20 mA / 0-10 V and 4-20 mA / 2-10 V.
Function
The measurable variable gets via an input protective circuit to the amplifier or impedance transformer. The
direct voltage obtained is converted into a load-independent direct-current and into an impressed direct
voltage. The electrical isolation is effected by means of an optocoupler. Both outputs are no-load resistant and
short-circuit proof. Any connection between both outputs will be unacceptable. An auxiliary voltage will be
required for all types.
Galvanic
Current
separation
impression
IE , U E
IA
Aux.
Voltage
UH
impression
UA
Technical data
Input
Input quantity
Rated values
Option
Overload permanent
Surge overload
Output
Output quantities
Double-output
Option
Dynamic
system
behaviour
Accuracy
Temperature range
Temperature influence
Influence of aux.
Load influence
External magnetic field
influence
Residual ripple
Response time
Option
No-load voltage
Current limitation
Testing voltage
(working voltage up
to 300V)
Testing voltage
(working voltage up
to 600V)
direct voltage or direct current

IgT-MU: 0-100 A up to 0-5 A, voltage drop 60 mV
UgT-MU: 0-5 mV up to 0-600 V, Ri = 100 kOhm up to 1 V, > 1 V 100 kOhm/V, max.
2 MOhm
Transmission of both polarities
Current 2-fold, voltage 5-fold / max. 830 V
Current 20-fold 1 sec., voltage 5-fold 1 sec.
Load independent direct current and direct voltage
0-20mA/0-750 Ohm of load and 0-10V max. load 20 mA as well as
4-20mA/0-750 Ohm of load and 2-10V max. laod 20 mA front-laterally switchable
bipolar output (e.g.. 20 mA 0 +20mA and 10 V 0 +10V)
Zero point rise (e.g.. 0 10 mA 20 mA and 0 5 V 10 V)
Frequency module - a value of 0 5 Hz up to 0 10 kHz
Open-collector NPN, max. 30V 100 mA loadable, impulse/break 50/50 %
Square wave signal 5V, max. 10 mA loadable, impulse/break 50/50 %
+/- 0,5 %
-15C up to +20C up to +30C up to +55 C
< 0,1 % at 10 K
none
none
none (up to 400 A/m)
< 15 mVss
< 300 ms (with frequency module < 400 ms)
< 200 s
max. 24 V
max. 2-fold in case of saturation
4 kV between input and output, input and aux., output and aux.
4 kV between output and aux., 5,2 kV between input and output
aux. 230 VAC and 110 VAC: 4 kV between input and aux.
aux. 24 VDC, 6-30 V AC/DC and 36-265 V AC/DC: 5,2 kV between aux. and input
MLLER + ZIEGLER GmbH & Co. KG, Industriestr. 23, D-91710 Gunzenhausen
Tel. +49 (0) 98 31.50 04 0, Fax +49 (0) 98 31.50 04 20
http://www.mueller-ziegler.de ,e-mail: info@mueller-ziegler.de
Adjustment
After taking off the plexiglass cover it is possible to adjust with the potentiometer which is named "SPAN" the final
value and with the potentiometer which is named "ZERO" the zero-point (zero point elevation only).
With the slide switch the output can be changed over between "LIVE ZERO" (4-20 mA/2-10 V) and "ZERO" (0-20
mA/0-10 V).
Regulations
EMC
Mechanical strength
Electrical security
DIN EN 61326
DIN EN 61010 part 1
DIN EN 61010 part 1
Housing all insulated, protection class II,
at a working voltage up to 300V (network to neutral conductor) degree of pollution 2,
overvoltage category CAT III
at a working voltage up to 600V (network to neutral conductor) degree of pollution 2,
overvoltage category CAT III
DIN EN 60688
DIN EN 61010 part 1, 3,52 kV 50 Hz 10 sec. and 5,2 kV 50 Hz 10 sec.
DIN EN 61010 part 1
Accuracy, overload
Separation
Air gaps and creep
distances
System of protection
Connection
DIN EN 60529 housing IP30, terminals IP20

DIN 43807
Auxiliary
voltage
230 V AC 20 %, 45-65 Hz, 2,5 VA

Option
Weight
110 V AC 20 %, 45-65 Hz, 2,5 VA

24 V DC, -15 % bis +25 %, 2 W, (EMC DIN EN 61326 class A)
6-30 V AC + DC or 36-265 V AC + DC, 2 VA, (EMC DIN EN 61326 class A)
170g
Dimensions
Installation
78
Attachement
108
35.2
84
2 2.5
snap-on mounting according to DIN EN 50 022

threaded terminal end 4 mm2 max.
Connection
DC-current measurement
1+
DC-voltage measurement
2+
SPAN
SPAN
ZERO
Z ERO
Type:
Type:
IgT - MU
UgT - MU
LIVE Z ERO
Z ERO
+13
+15
~+ 17
-14 mA
-16 V
~-18 UH
LIVE ZERO
ZERO
+13
+15
~+ 17
Transducers with frequency

module have no further
outputs and no "LIVE-ZERO"switching.
At the clamps +13 and 14
the frequency output is
available.
-14 mA
-16 V
~-18 UH
MLLER + ZIEGLER GmbH & Co. KG, Industriestr. 23, D-91710 Gunzenhausen
Tel. +49 (0) 98 31.50 04 0, Fax +49 (0) 98 31.50 04 20
http://www.mueller-ziegler.de ,e-mail: info@mueller-ziegler.de
MCR-f-UI-DC
INTERFACE
Data Sheet
100240_en_05
1
PHOENIX CONTACT - 10/2008
Description
MCR-f-UI-DC, the programmable MCR frequency

transducer, is a module for displaying and converting
frequencies up to120 kHz. On the input side, all common
frequency generator signals in 2, 3 and 4-wire technology,
and signals from incremental encoders can be collected.
The input impulses are evaluated using period
measurement and are then output by a processor as an
analog voltage or current value to match the measuring
range start and end value entered.
In order to achieve as short as possible reaction times, the
inputs of the frequency transducer have purposely been
designed without a frequency input filter. An automatic
measurement range selection function (autorange) ensures
that the measured value is always displayed with the
optimum resolution. Frequency interferences can, however,
lead to too large a division factor being selected for low input
frequencies. This in turn can result in an erratic output signal
(see "Operation with Disturbed Frequency Input Signals" on
page 6).
value. The depth of this filter can be set from 1 to 15 using

the membrane keyboard. The optimum filter depth depends
on the application.
In addition to the analog output, there is also a PNP
transistor switching output with a maximum carrying
capacity of 100 mA, for monitoring functions, for example
(not short-circuit proof).
Specially for rotational speed measurement, it is possible to
both enter the measuring range start and end value in
revolutions per minute (RPM), and to observe the
revolutions in RPM on the LCD (4-pos. + RPM as unit) during
operation.
In order to stabilize fluctuating input values, a filter function

has been implemented for conversion into the analog output
Make sure you always use the latest documentation.

It can be downloaded at www.download.phoenixcontact.com.
A conversion table is available on the Internet at
www.download.phoenixcontact.com/general/7000_en_00.pdf.
This data sheet is valid for all products listed on the following page:
MCR-f-UI-DC
Table of Contents
Description.................................................................................................................................. 1
Table of Contents ....................................................................................................................... 2
Ordering Data ............................................................................................................................. 3
Technical Data............................................................................................................................ 3
4.1
Dimensions .................................................................................................................................................... 5
Features ..................................................................................................................................... 5
Block Diagram ............................................................................................................................ 6
Operation with Disturbed Frequency Input Signals ..................................................................... 6

7.1
7.2
7.3
Measures to Counter External Influences....................................................................................................... 6

If Signal Level > 20 V...................................................................................................................................... 6
If Signal Level > 10 V...................................................................................................................................... 6
Resetting to Delivery State ................................................................................................................................. 6
Connection Technology.............................................................................................................. 7
10 Functions of the Membrane Keypad ........................................................................................... 9

10.1
Special Function of the Keys in Edit Mode ..................................................................................................... 9
11 Display on LCD....................................................................................................................................................... 9
11.1
11.2
11.3
11.4
Display Within Setting Range ......................................................................................................................... 9

Displaying the Switching Output................................................................................................................... 10
Messages in Operating Mode ...................................................................................................................... 10
Menu Guidance............................................................................................................................................ 10
12 Menu Flowcharts .......................................................................................................................11

12.1
12.2
12.3
Configuration of the Frequency Input Sequence of Menu .......................................................................... 11

Configuration of the Analog Input Sequence of Menu................................................................................ 12
Configuration of the Extended Mode Sequence of Menu .......................................................................... 13
13 Example: Configuration Based on a Frequency Input Signal .....................................................15

13.1
Continuation of the Configuration Example: ................................................................................................. 16
14 Configuration Software MCR/PI-CONF-WIN-... .........................................................................17

15 Application Example: Speed Measurement of a Drive ...............................................................17
100240_en_05
PHOENIX CONTACT
MCR-f-UI-DC
Ordering Data
Products
Description
Type
Order No.
Pcs./Pkt
MCR-f-UI-DC
2814605
Technical Data
General Data
Supply voltage
2030 V DC
Current consumption (without load)
< 60 mA (without switching output)
Transmission error
< 0.15% of end value (typ. 0.1%)
Temperature coefficient
< 0.015%/K (typ. 0,01%/K)
Test voltage:
Input/power supply
1.5 kV, 50 Hz, 1 min.
Input/output
1.5 kV, 50 Hz, 1 min.
Output/power supply
Protection circuit
1.5 kV, 50 Hz, 1 min.

Transient protection, polarity protection
Ambient temperature range
-20 C...65 C
Operation indicator
LC display
Control panel
Membrane keypad with 3 keys and LCD
Type of connection
Pluggable screw connection
Installation position/assembly
Any, preferably horizontal
Dimensions (W / H / D)
45 mm x 75 mm x 110 mm
Conductor cross section
0.2...2.5 mm2
Type of housing
ASA-PC (V0)
Measurement Input, Frequency Input

Frequency range
0.1 Hz120 kHz
Input sources
PNP transistor outputs

NPN transistor outputs
NAMUR initiators
Potential-free relay contact (Dry Contact)
Frequency generator
Sensor supply
ca. 15 V DC / < 25 mA
Input frequency / peak time / resolution
0.1 Hz120 kHz / 32 ms / 12 Bit
Signal level
2 Vpp (0.1 Hz120 kHz)

2 Vpp (8.0 Hz120 kHz)
18 Vpp (1.0 Hz120 kHz)
max. 30 V (incl. DC voltage)
Pulse length
1s
Current/Voltage Input
Input signal
010 V / 020 mA
Cut-off frequency
10 Hz
Ascent time (10...90%)
25 ms
100240_en_05
PHOENIX CONTACT
MCR-f-UI-DC
Output
Output signal
010 V / 100 V, 05 V / 50 V
or 0(4)20 mA / 200(4) mA
Output signal
max. 25 mA / 12.5 V
Current/voltage
Load
500 / 500
Current/voltage
25% / 25%
Alignment zero point / end value

Switching output
PNP transistor output,

switches the supply voltage to terminal SW,
can carry a load of 100 mA,
not short-circuit proof
Approval
U PROCESS CONTROL EQUIPMENT FOR

HAZARDOUS LOCATIONS 31ZN
Class I Div 2 Groups A, B, C, D
A) This equipment is suitable for use in Class I, Division 2, Groups A, B, C and
D or non-hazardous locations only.
B) Warning - explosion hazard - substitution of components may
impair suitability for Class 1, Division 2.
C) Warning - explosion hazard - do not disconnect equipment unless power
has been switched off or the area is known to be non-hazardous.
Conformance With EMC Guideline 89/336/EEC And Low Voltage Directive 73/23/EEC
Immunity to Interference According to EN 61000-6-21
Discharge of static electricity (ESD)
EN 61000-4-2
Criterion B2
Electromagnetic HF fields
EN 61000-4-3
Criterion A3
10 V/m
Fast transients (burst)
EN 61000-4-4
Criterion B2
Input/output/supply: 2 kV / 5 kHz
Surge voltage capacities (Surge)
EN 61000-4-5
Criterion B2
Input/output: 2 kV / 42
Supply: 1 kV / 2
Conducted interference
EN 61000-4-6
Criterion A3
Input/output/supply: 10 V
8 kV discharge in air
6 kV contact discharge
Noise Emission According to EN 61000-6-4

Noise emission of housing
EN 550114
Criterion A5
EN 61000 corresponds to IEC 61000
Criterion B:
Temporary impairment to operational behavior that is corrected by the device itself.
Criterion A:
Normal operating behavior within the defined limits.
EN 55011 corresponds to CISPR11
Criterion A:
100240_en_05
Area of application industry
PHOENIX CONTACT
MCR-f-UI-DC
4.1
Dimensions
45 mm
110 mm
75 mm
Figure 1
Dimensions
Features
Supply
Membrane keypad
Z
Inp ero
ut Fu
l
Inp lSca
ut le
is
Signal inputs
A
Ou nalo
tp g
ut
D
Ou igit
tp al
ut
Se Low
tp
oin
t
pl
ay
Re
se
10
Switching output
11
12
Se Hig
tp h
oin
t
di
ex
t.
od
8
C
5
I-D
60
U
4
-f 81
CR.:
Mrt.-Nr
A
DC
DC
DC
9
0
!
"
+8
Figure 2
100240_en_05
Features of MCR-f-UI-DC
Signal outputs
13
M
14
CR
15
-f16
UI
-D
C
1
2
,2
m
Na
IN
ur
C
m
V
4
+2
D
N
G
SW
N
NC
U
IO
PHOENIX CONTACT
MCR-f-UI-DC
Block Diagram
1
2
3
4
NPN
PNP
Dry
Contact
0-10 V
0-20 mA
Figure 3
7
7.1
5
6
+8,2V
9
0
DC
Namur
IN
DC
DC
f in
GND 1
"
mC
NPN
PNP
+15V
U in
I in
D
D
%
&
D
D
7.2
7.3
GND
SW
GND
NC
I OU T
U OU T
GND 2
Block diagram
Operation with Disturbed

Frequency Input Signals
Measures to Counter External Influences
+24 V
Use shielded conductors.

Lay cables in an appropriate manner (EMC-compliant).
Connect terminal 4 (GND 1) along the most direct route
to PE.
Resetting to Delivery State

Connect the top two pins of the pin strip (nearest
display) with the jumper.
Terminal 2 is now ready again for the connection of
NAMUR sensors.
If Signal Level > 20 V

Unplug the jumper located in the module after opening
the side flap. The jumper can be parked temporarily on
one of the three free pins.
Now route the frequency input signal to the module via
terminal 2. The signal is returned via terminal 4
(GND 1).
No additional settings are necessary.
If Signal Level > 10 V
Connect the bottom two pins of the pin strip with the
jumper.
Now route the frequency input signal to the module via
terminal 2.
No additional settings are necessary.
100240_en_05
PHOENIX CONTACT
MCR-f-UI-DC
Connection Technology
2-wire DC (mechanical contact)

1 +8,2 V
2 NAMUR
IN
3 f IN
bu
4 GND1
NPN
5 PNP
6 +15 V
2-wire DC NAMUR sensor

bn
MCR-f-UI-DC
bn
1 +8,2 V
2 NAMUR
IN
3 f IN
bu
4 GND1
NPN
5 PNP
6 +15 V
7 U IN
7 U IN
8 I IN
8 I IN
MCR-f-UI-DC
Alternatively, terminal 1 is also possible instead of terminal 6.

3-wire DC with:
PNP transistor output
bk
4 GND1
NPN
5 PNP
6 +15 V
bu
bu
7 U IN
8 I IN
8 I IN
bn
bk
pnp
bk
wh
100240_en_05
6 +15 V
3
3
bu
4 GND1
4 GND1
NPN transistor output

1 +8,2 V
2 NAMUR
IN
3 f IN
4 GND1
NPN
5 PNP
6 +15 V
bu
MCR-f-UI-D C
bu
NPN transistor with pull-up resistor
6 +15 V
4-wire DC with:
PNP transistor output
bn
4 GND1
NPN
5 PNP
6 +15 V
bn
npn
bk
wh
1 +8,2 V
2 NAMUR
IN
3 f IN
4 GND1
NPN
5 PNP
6 +15 V
7 U IN
7 U IN
8 I IN
8 I IN
MCR-f-UI-D C
bk
bk
npn
7 U IN
PNP transistor with pull-down resistor

bn
1 +8,2 V
2 NAMUR
IN
3 f IN
bn
MCR-f-UI-DC
1 +8,2 V
2 NAMUR
IN
3 f IN
bu
pnp
NPN transistor output
MCR-f-UI-D C
bn
PHOENIX CONTACT
MCR-f-UI-DC
4 GND1
NPN
5 PNP
6 +15 V
UB = 0 V DC
Supply of signal generator from the module

15 V/25 mA
1 +8,2 V
2 NAMUR
IN
3 f IN
4 GND1
NPN
5 PNP
6 +15 V
7 U IN
7 U IN
8 I IN
8 I IN
MCR-f-UI-DC
1 +8,2 V
2 NAMUR
IN
3 f IN
UB = 5-30 V DC
MCR-f-UI-DC
Incremental encoder with push-pull:

External supply of signal generator
The external supply can also be picked off from terminals

9 +24VDC and 0 GND.
3-way isolation is then no longer provided.
The connection from terminal block 4 GND1 to
terminal block 0 GND is essential!
K1, K2, K0
UB = 0 V
4 GND1
NPN
5 PNP
6 +15 V
K1, K2, K0
7 U IN
8 I IN
7 U IN
MCR-f-UI-D C
4 GND1
NPN
5 PNP
6 +15 V
8 I IN
100240_en_05
4 GND1
NPN
5 PNP
6 +15 V
K1, K2, K0
7 U IN
1 +8,2 V
2 NAMUR
IN
3 f IN
1 +8,2 V
2 NAMUR
IN
3 f IN
8 I IN
U input (direct current voltage)
15 V/25 mA
MCR-f-UI-DC
K1, K2, K0
1 +8,2 V
2 NAMUR
IN
3 f IN
Supply of signal generator from the module
I input (direct current)

1 +8,2 V
2 NAMUR
IN
3 f IN
4 GND1
NPN
5 PNP
6 +15 V
MCR-f-UI-DC
UB = 24 V DC
MCR-f-UI-DC
Incremental encoder with HTL logic:

External supply of signal generator
7 U IN
8 I IN
PHOENIX CONTACT
MCR-f-UI-DC
10
Functions of the Membrane

Keypad
10
Z
Inp ero
ut Fu
l
Inp lSca
ut le
is
A
Ou nalo
tp g
ut
D
Ou igit
tp al
ut
Se Low
tp
oin
t
pl
ay
Re
se
11
12
13
M
14
CR
15
-fUI
-D
C
Se Hig
tp h
oin
t
di
Figure 4
Membrane keypad
Press the keys briefly together (< 0.5 sec.):

Switches the module to extended edit mode
Press the keys briefly together: Ends edit
mode, without saving any settings that may
have been made.
Special Function of the Keys in Edit Mode
In edit mode for pulse input signals and for analog input signals, pressing the enter key
in
addition to the or key accelerates forward
or backward counting.
By releasing the key and then briefly pressing it
again, it is possible to carry out fine adjustments.
100240_en_05
Frequency input for NAMUR sensors with wire

break and short-circuit recognition. Settings
can be made in either Hz/kHz or RPM/kRPM
[Display: kRM] / MRPM [Display: MRM].
Voltage input 010 V
Adopts the current setting in edit mode and

switches automatically to the next value.
Frequency input for NAMUR, 2, 3 and 4-wire

sensors, incremental encoders with push-pull
and HTL output signal and dry contact. Settings
can be made in either Hz or RPM/kRPM [Display: kRM] / MRPM [Display: MRM].
Press the key for at least 2 seconds: Switches

the module to edit mode for analog input signals.
10.1
Display Within Setting Range
od
Press the key briefly (< 0.sec.): Switches the

module to edit mode for frequency input signals.
11.1
Current input 020 mA
Press the key briefly: The output value calculated is displayed.

By pressing the key again, you return to the current input measured value.
Display on LCD
ex
t.
11
ON delay of switching output.

(setting range 030 sec., default value = 0.00
sec.)
OFF delay of switching output.
sec.)
Setting POWER ON delay (switching output)
sec.) During this period, the switching output
does not react to events. This function is only of
effect directly after switching on the supply voltage.
Setting the wire-break detection time
(setting range 0.210.1 sec., default value =
10.1 sec.)
If no input signal is detected during this period,
"No Input" appears on the display and the outputs behave according to their settings
Setting the end value
(setting range 75125%, default value =
100%)
Setting the zero point in relation to the previously set
output signal: (setting range -5+5 mA / 2.5+2.5 V;
default value = 0 mA / 0 V)
Setting the division factor from 0.1 to 9999 (default value = 1.0). Slow positioning tasks require
holed coupling halves with multiple divisions
(factor > 1). Measuring the rotational speed of a
motor at the gearbox requires a small division
factor (factor < 1).
PHOENIX CONTACT
MCR-f-UI-DC
Setting the filter depth of the analog output

when using frequencies as input value (setting
range 1...15).
This function can only be configured using
the membrane keyboard.
11.3
Has fallen below the measuring range.

This message and the current frequency flash
alternately if the frequency falls below the bottom measuring range set.
Setting the analog output value

if the measuring range is fallen below
(setting range 0.0024.00 mA, or
0.0012.00 V)
Measuring range exceeded.

This message and the current frequency flash
alternately if the frequency exceeds the top
measuring range set.
Setting the analog output value

if the measuring range is exceeded
0.0012.00 V)
No input signal.
This message flashes for the following reasons:
1. No sensor connected!
2. For NAMUR: a) Short-circuit or b) Wirebreak!
3. Short-circuit frequency <-> GND!
4. No input signal found within the wire-break
detection time set (l.br.time).
Setting the analog output value with wire break

or an input signal that is not available
0.0012.00 V)
Saving. By pressing the
parameters are saved.
key, the set
By pressing the
key, the setting mode is interrupted without saving the parameters set.
By pressing the -key, the current settings are
overwritten by the default values. The parameters of the frequency input and analog input are
unaffected.
11.2
Messages in Operating Mode
11.4
Menu Guidance
In edit mode, the arrow points to the function to
be set.
Zero
Input
Full Scale Analog Digital Low

High
Input Output Output Setpoint Setpoint
Displaying the Switching Output

If "High Setpoint" is exceeded, the transistor
switches to "High",
If "Low Setpoint" is fallen below, it switches to
"Low" (with hysteresis).
If"High Setpoint" is exceeded, the transistor
switches to "Low",
If "Low Setpoint" is fallen below, it switches to
"High" (with hysteresis)
If "High Setpoint" is fallen below, the transistor
switches to "High".
If "High Setpoint" is exceeded, the transistor
switches to "High".
Transistor is permanently switched (N/C).
Transistor is permanently switched off (N/O).
Between "Low Setpoint" and "High Setpoint",
the transistor switches to "High".
If "Low Setpoint" is fallen below, and
"High Setpoint" is exceeded, the transistor
switches to "High".
100240_en_05
PHOENIX CONTACT
10
MCR-f-UI-DC
12
Menu Flowcharts
12.1 Configuration of the Frequency Input Sequence of Menu

Operating mode
Press briefly
f-input
Example
Example
Measuring
range start
Zero
Input
Zero
Input
Zero
Input
Example
Example
Zero
Input
Example
Example
+
Measuring
range end
Full Scale
Input
Full Scale
Input
Full Scale
Input
Full Scale
Input
all options
Analog
output
20 - 4 mA
4 - 20 mA
20 - 0 mA
0 - 20 mA
5-0V
0-5V
10 - 0 V
Analog
Output
all options
Switching
output
ON
Digital
Output
Example
Example
Example
+
Bottom
switching
point
Low
Setpoint
Low
Setpoint
Example
Low
Setpoint
Low
Setpoint
Example
Example
+
Top switching
point
High
Setpoint
High
Setpoint
High
Setpoint
High
Setpoint
Saving values
Operating
mode
Figure 5
100240_en_05
Configuration of the frequency input sequence of menu
PHOENIX CONTACT
11
MCR-f-UI-DC
12.2 Configuration of the Analog Input Sequence of Menu

Operating mode
Press for at least 2 seconds
Analog
input
Example
Measuring
range start
Zero
Input
Zero
Input
Example
Measuring
range end
Full Scale
Input
Full Scale
Input
All options
Analog
output
5- 0V
0- 5V
10 - 0 V
0 - 10 V
20 - 4 mA
4 - 20 mA
20 - 0 mA
Analog
Output
All options
Switching
output
ON
Digital
Output
Example
Bottom
switching
point
Low
Setpoint
Example
Low
Setpoint
Example
Low
Setpoint
Example
Top switching
point
High
Setpoint
High
Setpoint
High
Setpoint
Saving values
Operating
mode
Figure 6
100240_en_05
Configuration of the analog input sequence of menu
PHOENIX CONTACT
12
MCR-f-UI-DC
12.3 Configuration of the Extended Mode Sequence of Menu

Operating mode
Press briefly
+
Example
Example
Example
Example
Example
Example
Example
Example
Example
Example
Example
Example
ON delay
OFF delay
POWER ON
delay
Wire break
detection
End value
Zero point
Example
Division
factor
Output filter
function
Continued
Figure 7
100240_en_05
Configuration of the extended mode Sequence of menu (1)
PHOENIX CONTACT
13
MCR-f-UI-DC
Continuation of the Sequence of Menu:
Signal where
the measuring
range is fallen
below
Signal where
the measuring
range is
exceeded
No signal
Save
Do not save
Basic settings
Operating mode
Figure 8
100240_en_05
Configuration of the extended mode sequence of menu (2)
PHOENIX CONTACT
14
MCR-f-UI-DC
13
Example: Configuration Based on a Frequency Input Signal
The module MCR-f-UI-DC has the following functions:

Frequency range:
Output signal:
Switching behavior:
545700 Hz, 3-wire NPN sensor

420 mA
bottom switching point ("High" to "Low") at 15 Hz
top switching point ("Low" to "High") at 20 kHz
10 s
5s
1s
ON delay:
OFF delay:
Wire-break detection time:
Operating mode
Press briefly
f-input
3-wire NPN
Measuring
range start
Zero
Input
Zero
Input
Measuring
range end
Full Scale
Input
Full Scale
Input
Analog
output
Analog
Output
Analog
Output
Analog
Output
Switching
output
Digital
Output
Bottom
switching
point
Digital
Output
Low
Setpoint
Top switching
point
Digital
Output
Digital
Output
Low
Setpoint
+
High
Setpoint
High
Setpoint
Operating mode
Example
Figure 9
100240_en_05
Example: configuration based on a frequency input signal
PHOENIX CONTACT
15
MCR-f-UI-DC
13.1
Continuation of the Configuration Example:

Operating mode
Press briefly -> extended operating mode
+
ON delay
OFF delay
Wire break
detection time
Operating mode
Example
Figure 10
100240_en_05
Continuation of the configuration example
PHOENIX CONTACT
16
MCR-f-UI-DC
14
Configuration Software MCR/

PI-CONF-WIN-...
The MCR configuration software is available for the

configuration and visualization of all parameters for the
MCR-f-UI-DC frequency transducer.
The MCR-Software runs under Windows 95,
Windows 98, Windows NT, Windows ME,
Windows 2000 and under Windows XP.
The modules are configured via a serial interface. A label is
also created by the software that can be placed on the
module.
15
Application Example: Speed Measurement of a Drive
Figure 11
100240_en_05
Application example: speed measurement of a drive
PHOENIX CONTACT GmbH & Co. KG 32823 Blomberg Germany Phone: +49-(0) 5235-3-00
PHOENIX CONTACT P.O.Box 4100 Harrisburg PA 17111-0100 USA Phone: +717-944-1300
www.phoenixcontact.com
17
Sensorik
Level limiter electrode

Type E4B
I001
Version 5 (03/09)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Function ....................................................................................................................................................................... 2
6.2
Overview diagram ........................................................................................................................................................ 3
8.1
General notes on transport .......................................................................................................................................... 4
8.2
Interim storage............................................................................................................................................................. 4
Assembly.................................................................................................................................................................... 5
9.1
Assembly of electrode rod ........................................................................................................................................... 5
9.2
Installation of level limiter electrode ............................................................................................................................. 6
9.3
Installation variants ...................................................................................................................................................... 7
9.4
Shortening the electrode rod........................................................................................................................................ 9
9.5
Removal of level limiter electrode ................................................................................................................................ 9
10
11
Setting and Adjustment........................................................................................................................................... 11
12
Start-up ..................................................................................................................................................................... 11
12.1
Setting the switching point ......................................................................................................................................... 11
12.2
Heating up on commissioning.................................................................................................................................... 11
13
Operation.................................................................................................................................................................. 11
13.1
Behaviour in the event of operating faults.................................................................................................................. 11
14
15
15.1
Level limiter electrode operating test ......................................................................................................................... 14
15.1.1 Level limiter electrode operating test with hot water boiler systems .......................................................................... 15
15.1.2 Level limiter electrode operating test with steam boiler systems ............................................................................... 15
15.2
Testing the level limiter electrode .............................................................................................................................. 15
15.3
Internal protective pipe inspection (only steam generators)....................................................................................... 16
15.3.1 Straight protective pipe installation ............................................................................................................................ 16

15.3.2 Angled protective pipe installation ............................................................................................................................. 16
15.4
Measuring and water level indicating module inspections (only steam generators)................................................... 16
16
Page 1 of 16

Type E4B
I001
Version 5 (03/09)
H001 Switching amplifier B3
The level limiter electrode E4B may only be used in connection with the switching amplifier B3 (see Operating Instructions
H001 Switching amplifier B3) for level limitation in shell boilers with boiler water conductivity 30 S/cm (related to 25C).
Safety
Danger! If this level limiter electrode fails, it can cause serious damage and loss of life or serious injury.
The level limiter device is a device that is of absolute fundamental importance for the safety of the boiler system.
For safety reasons, work on such safety devices should only be carried out by Loos International or specialist
staff authorised by Loos International.
6
6.1

Function
The level limiter electrode E4B is, in combination with the switching amplifier B3 (see Operating Instructions H001), is a
special type of water level limiter. The combination of equipment recognises the minimum permitted water level LW (= low
water) in steam and hot water generators.
The function of the level limiter device is based on the different conductivity of water and steam. When the level limiter
electrode is immersed and removed, a bridge switching in the switching amplifier B3 is unbalanced. This signal is amplified
and switches the output relay of the switching amplifier, which, with its contacts in the safety chain of the firing, triggers a
fault shutdown.
The LW switching point is permanently set through the place of installation, location of the level limiter electrode and
electrode rod length and can only be changed as described in Chapter 9 "Assembly".
Page 2 of 16

Type E4B
I001
Version 5 (03/09)
If the level falls below the LW switching point or if the permitted monitoring current of the insulation monitoring is exceeded,
then the light-emitting diode (LED) on the switching amplifier goes off, the relay in the switching amplifier returns to the
starting position, and the firing is shut down due to a fault.
With steam generators, the level limiter electrode is installed in a protective pipe to avoid any dangerous incorrect
operations as a result of foam formation in the boiler water (foam simulating water).
With hot water generators, it is usually installed in the supply flow adapter piece without any other protection.
6.2
Overview diagram
A=
Electrode thread G 1"
B=
Seal seating
C=
Sealing ring D 33 x 42 x 2
D=
Cable connection socket
E=
Cooling section
F=
Electrode body
G=
Hexagonal bolt
H=
Electrode rod connection
I=
Electrode rod
K=
Lock nut
L=
Teflon insulator
M=
Inspection openings
N=
Insulation monitoring
L1 = Electrode rod length (depending on installation

situation)
Figure 1: Level limiter electrode consisting of electrode body and electrode rod
Page 3 of 16

Type E4B
I001
Version 5 (03/09)
Working pressure:
32 bar at 238C
Test pressure:
41.6 bar
Mechanical connection:
Thread G 1 DIN ISO 228
Design:
Electrode with insulation monitoring
Materials:
Electrode rod:
1.4104
Electrode thread: 1.4104

Lock nut:
A4-70
Min. nec. boiler water conductivity:
30 S/cm (in relation to 25C)
Electrical connection:
4-pole appliance plug, core cross-section 0.75 mm2
max. connection cable length
50 m
Cable type
screened cable Liycy 4 X 0.75mm
Cable socket connection
see Figure 7
Protection type:
IP 54 acc. to DIN 40050
Permitted working temperature at cable

connection socket base with connecting cable:
minimum +5C, maximum + 70C
Permitted ambient temperature:
maximum 70 C
8
8.1

Measurement and control devices are sufficiently protected and packed for transport at the factory.
Avoid vibrations as far as possible.
Always protect equipment from the effects of wetness and damp.
If damage to the packaging is observed when the delivery is received, the driver must be informed about this damage.
When the driver hands over the delivery, he must confirm in writing on the receipt slip that the packaging is damaged.
8.2
Interim storage
Page 4 of 16

Type E4B
I001
Version 5 (03/09)
9
9.1
Assembly
Assembly of electrode rod
If the electrode rod is not yet attached to the electrode body, the following steps should be followed after it has been put
together:
Important! Only original Loos stainless steel rods may be used as electrode rods.
Tools required:
Ring spanner SW 10 DIN 838

Open-ended spanner SW 10 DIN 3110
Twist electrode rod (I) with attached lock nut (K) into the electrode rod connection (H) with ring spanner SW10 and lock with
open-ended spanner SW10 at electrode rod connection (H) (see Figure 2). Only stainless steel nut should be used.
Important! Ideally, the electrode is laid on an even base, held on the electrode rod connection (H) using an
open-ended spanner SW 10 and the lock nut (K) tightened. The electrode rod connection (H) must not be
allowed to turn. Under no circumstances should the electrode body (F) be tensioned in a vice or held on the
hexagonal bolt (G) with a ring spanner. These could cause damage to the electrode body and subsequent
malfunctioning of the level limiter electrode.
Figure 2: Screwing in the electrode rod

Checking the axial alignment of the E4B
The level limiter electrode (without cable connection socket (D)) must be rolled onto an even surface and the height of the
top of the electrode rod measured. The difference between the upper and lower measurement point may not exceed 12 mm.
If the value is more than 12 mm, the axial alignment must be adjusted by carefully pressing the electrode rod.
Figure 3: Checking the axial alignment of the electrode rod
Important! Under no circumstances should electrodes with an amplitude greater than 12 mm be installed, since
there would then be a danger that the tip of the electrode rod would touch the installation connector or protective
piping and would therefore not function.
Page 5 of 16

Type E4B
I001
Version 5 (03/09)
9.2
Installation of level limiter electrode

Danger! Serious scalding is possible. The installation of the level limiter electrode may only be carried out if the
boiler or the system into which the level limiter electrode is to be installed is guaranteed unpressurised and has
been sufficiently cooled.
Tools required: Ring spanner SW 32 DIN 838 (do not use an open-ended spanner!)
Check sealing surfaces on threaded connectors or flange covers, clean if necessary.
Before screwing in the level limiter electrode, the Teflon insulator (L) must be cleaned with a clean cloth in the
longitudinal direction. It must be absolutely free from grease and oil.
Place the sealing ring (C) supplied onto the seal seating (B) of the level limiter electrode. Only the original sealing ring
supplied, D 33 x 41 x 2 DIN 7603-Cu, may be used.
Do not seal with hemp or PTFE tape under any circumstances!
Important! The Cu sealing ring may only be used once.
Important! The electrode rod of the level limiter electrode is, if necessary, to be shortened in such a way (see
Section 9.4 "Shortening the electrode rod" and Section 12.1 "Setting the switching point") that the trigger point in
the operating state is at the low water marking or in the region of max. 10 mm above to max. 5 mm below low
water.
When installing or re-installed, care must be taken to ensure that the tip of the electrode rod is not bent and does
not have any earth contact.
Coat the screwing-in thread (A) with a small quantity of assembly paste (e.g. HT Optimol Paste HT).
Screw the level limiter electrode into the threaded connector or flange cover and tighten it with the open-ended spanner
SW 32 at the hexagonal bolt (G). The tightening torque when cold is 160 Nm. The screw-in bore hole must comply with
DIN 3852 Part 2, G 1, DIN ISO 228, form X or Y, standard design.
The electrode body should not be integrated in the insulation.
Page 6 of 16

Type E4B
I001
Version 5 (03/09)
9.3
Installation variants
Figure 4: Angled installation for hot water systems

D15.502
Upper connection socket for

measuring and water level
indicating module to the boiler
body
D15.503
Lower connection socket for

indicating module to the boiler
body
D15.510
Measuring and water level

indicating module internal
diameter
(D2 100 mm)
D16.507
Drainage connection for

indicating module
(D3 = min. R 3/8")
Figure 5: Installation in measuring and water level indicating module (also see Operating Instructions
C016)
Page 7 of 16

Type E4B
I001
Version 5 (03/09)
Figure 6:
O=
Straight installation of protective Figure 7: Angled installation of protective pipe, steam generator
pipe, steam generator
Clear diameter of protective electrode duct
O=
(D2 100 mm)

P=
compensating bore on the water side
(D2 100 mm)

P=
(D3 = min 15 mm)

R=
Compensating bore on the steam side
Clear diameter of protective electrode duct

compensating bore on the water side
(D4 = min surface 300 mm)
R=
(D1 = min 20 / max.1/3 x D2)
Compensating bore on the steam side

(D1 = min 20 / max.1/3 x D2)
S=
Cover plate
T=
Hexagon bolt M12 X 20
Page 8 of 16

Type E4B
I001
Version 5 (03/09)
Figure 8: Cover plate (S) detail with inclined steam generator

installation
9.4
Shortening the electrode rod
If the electrode rod (I) has to be shortened, it must be unscrewed from the level limiter electrode. For this, the lock nut (K) on
the electrode rod connection (H) is to be loosened with the ring spanner SW10 and held with the open-ended spanner
SW10 at the electrode rod connection (H) (see Figure 2).
Important! Ideally, the electrode is laid on an even base, held on the electrode rod connection (H) using an
open-ended spanner SW 10 and the lock nut (K) tightened. The electrode rod connection (H) must not be
allowed to turn. Under no circumstances should the electrode body (F) be tensioned in a vice or held on the
hexagonal bolt (G) with a ring spanner. These could cause damage to the electrode body and subsequent
malfunctioning of the level limiter electrode.
The removed electrode rod must be shortened in accordance with the requirements given in Chapter 12.1 using an iron saw
and the cut edge must then be deburred.
After shortening has been completed, the assembly of the electrode rod should be carried out according to Chapter 9.1 and
the axial alignment checked.
9.5
Removal of level limiter electrode

Danger! When the level limiter electrode is loosened, steam or hot water under high pressure may emerge,
causing serious scalding all over the body. Only remove the level limiter electrode if the boiler or system in which
the level limiter electrode is located is guaranteed unpressurised and has sufficiently cooled down.
Tools required: Ring spanner SW 32 DIN 838
Switch off power supply.
Check that the boiler or system in which the level limiter electrode is installed is unpressurised (e.g. by pressure
displays attached to the system).
Disconnect table connection socket (D) from bottom part of plug.
Slowly remove the level limiter electrode with a ring spanner SW 32 on the hexagonal bolt (G).
Important! The electrical connection is a part of the component inspection. If the required connection regulations
are not complied with, the component inspection is invalid. The electrical connection of the electrode may only be
carried out by Loos Service or a qualified electrician.
The level limiter electrode may not be opened!
Page 9 of 16

Type E4B
I001
Version 5 (03/09)
The level limiter electrode is electrically connected via the four-pole cable connection socket supplied. The allocation of the
cable connection socket is carried out in accordance with the connection plan. The following points should be noted:
Cable inlet at cable connection socket with cord grip PG 11
Cable outlet and max. cable length according to Chapter 7 "Technical Data" .
Screening at connection terminal in control cabinet

1 = brown
2 = white
3 = green
4 = yellow
Figure 9: Pin allocation of cable connection socket with colours of connection cable
Colours of connection cables
Shielding
Cable LIYCY 4 x 0,75 mm
Cable connection socket
Connectors on level limiter electrode
Isolation monitoring
Electrode rod
Figure 10: Connection diagram level limiter electrode
Page 10 of 16

Type E4B
I001
Version 5 (03/09)

The level limiter electrode is set during the initial commissioning.
12 Start-up
The initial commissioning or re-commissioning after replacement of the level limiter electrode may only be carried
out by Loos International Service or by specialist personnel who have been expressly authorised by Loos
International to carry out this work.
12.1 Setting the switching point

The electrode rod is usually already cut to the correct length by the factory. Operating tests by means of lowering the boiler
water level and checking the response of the burner safety locking should be carried out with initial commissioning and any
work at the level limiter device on principle. The boiler system may only be (re)started after successful testing.
Note! If, in the hot state, larger switching point deviations exist than those described in section 12.2, a
modification of the switching point must be carried out. This may only be done by Loos International service
engineers or by specialist staff who have been expressly authorised by Loos International to carry out this work.
Note: With conductivities of 30 S/cm in the boiler water, especially at the initial start-up, it may happen, as a
result of the active principle, that the level limiter electrode is triggered prematurely. To avoid this, the boiler
water conductivity should be increased to 30 S/cm e.g. through the addition of salt-forming oxygen binders
(sodium sulphate).
12.2 Heating up on commissioning

Any leak at the screw-in thread (A) can generally only be rectified by tightening with a ring spanner size 32. If the boiler is
cold and the electrode is new, it is possible that water or steam may leak out of the inspection openings (M) at the electrode
body (F). In this case, the boiler is to be heated up to working pressure, and the electrode will then generally seal itself.
Note: Switching point deviations in the range from 10 mm above the LW marking to 5 mm above the LW
marking in the working state can be ignored.
13 Operation
For normal operation, no further measures are necessary apart from the tests described in the Chapter "Care and
maintenance".
13.1 Behaviour in the event of operating faults

Danger! There is a danger from lack of water. It can cause serious damage to the boiler, or even completely
destroy the boiler. In extreme cases, it may cause extremely serious damage to the plant, and people may suffer
fatal injuries.
If there is a shortage of water, the level limiting device should be triggered, causing the firing to be switched off and locked.
If the level limiter fails, the boiler heating must be switched off immediately. If necessary, the emergency stop switch must be
used.
You should carry out the following measures, depending on the level visible in the level indicator:
Water still visible in level indicator:
Switch on the feed water supply immediately by hand.
The steam shut-off valve must be closed immediately. This prevents the boiler from losing steam quickly. The pressure
safeguard valve must be functioning properly to prevent any damage elsewhere.
Page 11 of 16

Type E4B
I001
Version 5 (03/09)
Water no longer visible in the level indicator:

Danger! Do not feed water in the boiler under any circumstances. This will inevitably destroy the boiler. In
extreme cases, it may cause extremely serious damage to the plant, and people may suffer fatal injuries.
The steam shut-off valve must be closed immediately. This prevents the boiler from losing steam quickly. The pressure
safeguard valve must be functioning properly to prevent any damage elsewhere.
The boiler may only be started up again when the causes for the failure of the level limiter have been properly removed and
a competent person allows the boiler to be fired again after a corresponding inspection. Loos International recommends that
this inspection is carried out by suitably trained Loos International service engineers or by people who have expressly
If lack of water has caused damaged to the boiler (e.g. deformation of the flame tube or similar), the boiler must be shut
down immediately. The boiler may only be started up again when the damage that has occurred has been properly repaired
and a competent person allows the boiler to be fired again after a corresponding inspection. Loos International recommends
that this inspection is carried out by suitably trained Loos International service engineers, unless a monitoring organisation
has been consulted.
Following operating phases with disturbed water conditions (ingress of hardness, foreign matter etc.), the boiler and all
safety-relevant equipment must be inspected separately in coordination with a technical expert.

repair:
Observation/fault:
Level limiter device not working
Cause
Repair
No supply voltage
Check voltage supply, restore power
Cable connection socket not mounted
Plug cable connection socket onto plug of electrode

and screw on tightly
No function
Check cable connection socket connection
Defective micro-fuse at B3 switching amplifier
Replace micro-fuse
By whom?
Observation/fault: Level limiter device switches off at too high a level

Cause
Repair
Boiler water quality not in accordance with

Operating Instructions B002 "Guideline on water
quality for steam boiler systems", e.g. foaming
(especially conductivity; Ks8,2; overall hardness,
KMnO4 consumption)
Set boiler water according to Operating Instructions

B002 "Guideline on water quality"
By whom?
Empty boiler and refill with prepared feed water
Page 12 of 16

Type E4B
I001
Version 5 (03/09)
Boiler water conductivity 30 S/cm
Increase boiler water conductivity by increased

dosage (e.g. of sodium sulphite)
Electrode rod of level limiter electrode is dirty
Remove level limiter electrode in unpressurised

state and clean
Electrode rod too short
Install longer electrode rod
Observation/fault:
Level limiter device switches off at too low a level
Cause
Repair
Protective piping of level limiter electrode too short
Clean boiler and protective pipe
By whom?

Electrode rod too long
Observation/fault:
Shorten electrode rod
Level limiter device switches off
Cause
Repair
Boiler water quality does not comply with Operating

Instructions B002 "Guideline on Water Quality for
Steam Boiler Systems", e.g. foaming (especially
conductivity; Ks8,2; overall hardness, KMnO4
consumption)
Adjust boiler water so that it complies with

Operating Instructions B002 "Guideline on Water
Quality"
Shut-off valves in suction and pressure pipes not

open
Open all shut-off valves in suction and pressure

pipes
Too much steam removed from boiler
Throttle steam shut-off valve
Feed pump feed insufficient water or no feed water

at all
See Operating Instructions for centrifugal pump

E001
Desalting volume too high
Check water treatment and condensate
By whom?
Empty boiler and fill with treated feed water
Check limit switch positions of desalting control

valve
Feed pump does not switch on
Check switch points of level regulation and dry run

protection
Page 13 of 16

Type E4B
I001
Version 5 (03/09)
Cause
Repair
By whom?
Disconnect frequency converter for feed pump, if

provided, from power supply and then reconnect
after 30 s
Feed water control valve, if provided, not working
properly
Check feed water control valve, check limit switch

position
Filter between feed water contain and boiler intake

blocked
Clean filter valve
Level limiter electrode not immersed (start-up

states, keeping warm..)
Check water level in boiler
Insulation monitoring triggered (short circuit at pin

contacts - sockets between 3 and PE, or 4 and PE)
Replace level limiter electrode

state and clean
Pause times for automatic blow-down set too short
Increase pause times

state and clean
Observation/fault:
Level limiter device does not switch off when tested according to Operating
Instructions H001
Cause
Repair
Protective pipe of level limiter electrode too short
Clean boiler and protective pipe
By whom?

Electrode rod of level limiter electrode touching the
protective pipe
Check installation situation and put right
Cable connection between control cabinet and level

limiter electrode has short circuit
Find cause of short circuit and put right

15.1 Level limiter electrode operating test
The operating test of the level limiter electrode should be carried out monthly.
H001 Switching amplifier B3
Page 14 of 16

Type E4B
I001
Version 5 (03/09)
15.1.1 Level limiter electrode operating test with hot water boiler systems
For inspecting the level limiter electrode switch off the burner and separate the boiler from the hot water network via the
supply and return flow shut-off valve. Open the filling level checking device (if it is located below the level limiter electrode)
for draining the water to cause triggering of the level limiter electrode. If the filling level checking device is located higher,
lower the water level of the locked boiler via the drain shut-off valve and use the filling level checking device as ventilation
during the lowering process.
Danger! Severe scalding injuries are possible. If the filling level checking device is a blanking plug type at the
supply flow adapter piece, it may under no circumstances be opened during boiler operation or when the hot
water generator is cold and pressurized. Ensure that the hot water generator is unpressurized before opening the
blanking plug.
The level limiter of a pressurized or hot boiler can only be checked if the discharged water can be drained safely
via the filling level checking device.
When the level limiter electrode switching point is reached the boiler control should carry out a shut down on faults.
If the shut down on faults does not take place, shut down the boiler immediately and look for the cause of the failure.
Important! Do not recommission the plant until you have determined and eliminated the cause of malfunction.
Close the filling level checking device again tightly after successful completion of the level limiter electrode operating test.
Slowly open the supply and return flow shut-off valves for restarting the boiler. The air bubble caused by the lowered water
level must be discharged from the system with an automatic deaeration valve.
15.1.2 Level limiter electrode operating test with steam boiler systems
For inspecting the level limiter electrode switch off the burner and separate the boiler from the steam network via the steam
extraction shut-off valve.
Lower the water level of the boiler (being shut-off) via the quick shut-off blow down valve to cause triggering of the level
limiter electrode (see Operating Instructions K005).
When the level limiter electrode switching point is reached the boiler control should carry out a shut down on faults.
If the shut down on faults does not take, shut down the boiler immediately and look for the cause of the failure.
Important! Do not recommission the plant until you have determined and eliminated the cause of malfunction.
Refill and restart the boiler after successful completion of the level limiter electrode operating test (see Operating
Instructions C003/C018).
When carrying out the operating test while the boiler is cold, the level limiter device should already respond before the low
water level mark is reached (due to the linear expansion of the electrode rod during boiler operation).
Danger! The electrode switching point should be in the range of 10 to 15 mm above the low water level mark. If
this is not the case, please contact the Loos International Service or expert staff expressly authorised for this
work by Loos International. The electrode rod must be adapted before continuing to operate the system!
15.2 Testing the level limiter electrode

The electrode rod is to be removed once a year, from a pressure-free boiler, checked for soiling and deposits and cleaned if
necessary.
Important: Do not bend the electrode rod during cleaning and avoid hard impacts against the rod.
If the measurement medium is seriously soiled in normal operation, or if the chemical measured values for two consecutive
measurements are outside the limits that are given in Operating Instructions B002/B004 (Guideline on Water Quality), this
inspection or cleaning process must be carried out every three months at least.
Page 15 of 16

Type E4B
I001
Version 5 (03/09)
Installing and removing the measuring transducer is described in the chapter on Assembly.
In addition, follow the instructions given in Section 12.2. "Heating up on commissioning".
15.3 Internal protective pipe inspection (only steam generators)

The safety of the boiler system depends to a large extent on the proper function of the water level regulator and limiter
device. It is therefore essential, as part of the internal testing, at every three years at the most, to test the electrode
protective pipe (O) for impurities and the free passage of the water (P) and steam compensating openings (R).
In the case of boiler systems with a level limiter device, this inspection must be carried out every year.
At the electrodes, the measurement surface must be cleaned. It is assumed that the boiler is operated according to the
water guidelines (see Operating Instructions B002) laid down by Loos International.
15.3.1 Straight protective pipe installation

To test the protective pipe when the boiler is unpressurised and cooled, the level limiter electrode (according to Section 9.5
"Removal of level limiter electrode") and all other electrodes (according to their operating instructions) that are installed in
the protective pipe must be removed. A visual inspection must be carried out via the screw-in thread of the level limiter
electrode to inspect the protective pipe for dirt; if necessary, it must be cleaned with a high-pressure cleaner.
All electrodes must then be re-installed according to their operating instructions.
15.3.2 Angled protective pipe installation

To test the protective pipe when the boiler is unpressurised and cooled, the level limiter electrode (according to Section 9.5
"Removal of level limiter electrode") and all other electrodes (according to their operating instructions) that are installed in
the protective pipe must be removed. After this, the cover plate (S) must be removed by loosening the hexagon bolts (T).
The protective pipe must be inspected for dirt and cleaned if necessary with a high-pressure cleaner.
Afterwards, the cover plate (S) must be attached to the protective pipe with the hexagon bolts (T) and all electrodes reinstalled according to their operating instructions.
Important! Install the cover plate (S) according to the marking on the plate (see fig. 8).
15.4 Measuring and water level indicating module inspections (only steam generators)
C016 Measuring and water level indicating module
Level limiter electrode E4B (Limiter 1):
Material number 085320.2
Level limiter electrode E4B (Limiter 2)
Electrode rod for level limiter electrode E4B:
(max. length)
Sealing ring 33 x 41 x 2:
HT Optimol assembly paste (packaging unit 100 g)
Material number 10024910
Page 16 of 16
Pressure transducer
for liquid and gaseous media, with electric locking
I003
Version 5 (05/05)
Contents
1
Safety .......................................................................................................................................................................... 2
6.1
Construction ................................................................................................................................................................. 3
6.2
Function ....................................................................................................................................................................... 3
Technical Data (Dimensions, Weight, Operating Conditions) ................................................................................ 4
8.1
8.2
Interim storage ............................................................................................................................................................. 4
Assembly .................................................................................................................................................................... 5
10
11
11.1
Steam boiler ................................................................................................................................................................. 5
11.2
Hot water boiler ............................................................................................................................................................ 5
12
Start-up ....................................................................................................................................................................... 5
13
14
14.1
Inspection periods ........................................................................................................................................................ 7
14.2
Running the pressure limiter test.................................................................................................................................. 7
14.2.1 Steam boiler ................................................................................................................................................................. 7

14.2.2 Hot water boiler ............................................................................................................................................................ 8
15
Page 1 of 8
Pressure transducer
I003
Version 5 (05/05)
The pressure transducer can be used as:
Pressure monitor
The designation "pressure monitor" also includes the function of pressure switch.
Pressure limiter
If used as a pressure limiter, the electrical connection must be in accordance with the Loos International locking
switching.
Permitted media within the parameters listed in the section "Technical Data":
Steam, hot water, condensate, feed water, oil
Safety

Danger! Incorrect or faulty installation and/or start-up of the pressure transducer can cause failure of the device
and thus serious damage through the leakage of hot media, which can cause severe scalding which can be fatal.
If this happens, the system must be turned off and secured immediately.
The system may only be started up again if the cause of the failure of the pressure transducer has been properly repaired
and an expert allows the system to be restarted after an appropriate test has been carried out. Loos International
recommends that this test is carried out by suitably trained Loos International service engineers or by people who have been
Page 2 of 8
Pressure transducer
I003
Version 5 (05/05)
6
6.1

Construction
Brief description of the device

Compact, vibration-resistant design
Brass pressure sensor
Housing sealed light-tight
Transparent cover in impact-resistant, self-extinguishing Thermoplast
Setpoint value with display, which can be set from outside, with stop that can
be sealed.
Scale in bar with conversion aid for MPa
Appliance plug with Pg11 power socket in accordance with DIN 43650
Figure 1: Pressure transducer
6.2
Function
The pressure transducer is used for the regulation, monitoring and ensuring of pressures in liquids, gases and vapours.
Xs
Xsd
If the pressure rises by the switching difference Xsd above the lower switching
point Xs, then the contact switches from 1-2 to 1-3.
If the pressure falls below the lower switching point Xs, then the contact
switches from 1-3 to 1-2 um.
3
1
Figure 2: Setting the switching points of the pressure transducer
Page 3 of 8
Pressure transducer
I003
Version 5 (05/05)
Permitted ambient temperature
-20 ... +70 C
Permitted temperature at sensor
max. 70 C
Permitted ambient humidity
Class D (DIN 40040)
Permitted vacuum loadbearing capacity
- 1 bar
Permitted contact load
4 A, 250 V AC; 50 W, 250 V DC;

min. 100 mA, 24 V
Degree of protection
IP 65 (EN 60529)
Connecting pin
G 1/2 - external thread
Max. pressure
Weight
bar
Adjustable switching
difference Xsd
bar
bar
kg
012615.1
0 1.6
0.2 ... 0.75
12
0.5
DSB143-F911
012616.1
06
0.3... 1.6
16
0.5
DSB146-F911
012617.1
0 10
0.7 ... 4
30
0.4
DSB152-F911
012618.1
6 16
1 ... 4.3
30
0.4
DSB158-F911
012619.1
0 - 25
1 ... 7.5
60
0.4
DSB170-F911
012620.1
5 40
1.4 ... 7.5
60
0.4
Loos Int.
Setting range Xs
ID number
DSB138-F911
Type
Table 1: Parameters of the pressure transducer
8.1
Measurement and control devices are sufficiently protected and packed for transport at the factory.
Avoid vibrations as far as possible.
Always protect equipment from the effects of wetness and damp.
If damage to the packaging is observed when the delivery is received, the driver must be informed about this damage.
When the driver hands over the delivery, he must confirm in writing on the receipt slip that the packaging is damaged.
8.2
Interim storage
Page 4 of 8
Pressure transducer
I003
Version 5 (05/05)
Assembly
The measurement and control equipment may only be installed by specialists with the relevant professional
training who have the necessary specialist knowledge.
The pressure transducers may only be used with a medium temperature 70C, and only with a siphon pipe as a protective
device.
Note: If the medium contains ammonia, the parts of the pressure transducer in contact with the medium must be
made from stainless steel.
Pressure transducers with a safety function that are used as pressure limiters may only be used with the corresponding Loos
International locking switching.

For safety reasons, this work may only be carried out by Loos International or by specialist staff authorised by
Loos International.
Important! The switching point must always be set sufficiently below the trip pressure of the pressure
safeguard valve. Setting a pressure that is too close to the trip pressure of the pressure safeguard valve can,
through the easy opening, cause damage to the seat and cone of the pressure safeguard valve. this will be
apparent from the frequent or continuous leakage of vapours at the blow-off line of the pressure safeguard valve.
11.1 Steam boiler

Correctly setting the pressure limiter has a major effect on the working life of the boiler and the pressure safeguard valve.
Too small a switching difference between the firing switchoff point and the setting of the pressure switch with safety function
will cause increased wear and unnecessary fault disconnection. It should be noted that the pressure can rise further after the
firing has been switched off (through after-heating) or in the case of systems with quick shut-off devices (e.g. solenoid valves
which suddenly interrupt the flow of steam), so that the switching point difference between normal shut-down and limiter
should be kept as large as possible to avoid unnecessary shut-down on faults. If the pressure difference between the switchoff pressure of the pressure limiter and the trip pressure of the pressure safeguard valve is too low, this can start to leak in a
very short time (see Operating Instructions K002 Full-Lift Safety Valves).
11.2 Hot water boiler

Correctly setting the pressure limiter has a major effect on the working life of the pressure safeguard valve. If the pressure
difference between the switch-off pressure of the pressure limiter and the trip pressure of the pressure safeguard valve is too
low, this can start to leak in a very short time (see Operating Instructions K002 Full-Lift Safety Valves).
12 Start-up
The start-up of measurement and control equipment may only be carried out by specialists with the relevant
professional training who have the necessary specialist knowledge.
The start-up of components supplied by Loos International may only be carried out by staff of Loos International
or by people who have been expressly authorised to carry out this work by Loos International.
The siphon pipe must be filled with distilled water before start-up.
Page 5 of 8
Pressure transducer
I003
Version 5 (05/05)

repair:
Observation/Fault:
Delayed switching off of burner

Blow-off of pressure safeguard valve
Triggering of pressure transducer
Cause
Repair of fault
Impermissibly high rise in pressure if used as

pressure monitor:
Check setting of switching points/

reset if necessary
Check existing control parameters
Impermissibly high rise in pressure if used as

pressure limiter
Check setting of switching points/

reset if necessary.
Check existing control parameters and/or pressure
monitor setting
Incorrect setting of switching points
Set switching points correctly
Hydraulic seal and connecting pipe dirty
Remove hydraulic seal, clean and test again after

re-installing
By whom?
With permanently welded hydraulic seals that

cannot be closed off, make boiler unpressurised,
loosen drainage plug and push wire or similar
through the pipe.
Remove pressure transducer and check that
openings are clear, then rinse through with water,
re-install pressure switch and test
Sensor breakdown
Replace pressure transducer
Temperature at pressure switch too high
Install siphon pipe
Check siphon pipe,

check pressure transducer, replace if necessary,
use new appliance with pressure monitors in any
case.
Ambient temperature < 70
Check pressure transducer and replace if
necessary,
case
Page 6 of 8
Pressure transducer
I003
Version 5 (05/05)
Cause
Repair of fault
Temperature too low/frost at hydraulic seal
Ensure ambient temperature > 3C

Check pressure transducer and replace if
necessary,
case.
Shut-off valve at pressure transducer closed
Open shut-off valve
Fault in or incorrect setting of the pressure

maintenance unit (in hot water systems)
Repair fault in pressure maintenance unit or change

the switching on/off point of the pressure
maintenance unit
By whom?

Warning! Danger of scalding! Blowing through with the medium is not allowed, because it could cause faults and
damage to the pressure transducer and injuries. Cleaning can be carried out using compressed air.
The pressure transducer itself is maintenance-free.
At monthly intervals, the supply lead and the hydraulic seal should be rinsed through, checked to ensure there are no
blockages and cleaned if necessary.
Stick to the following sequence:
1. Ensure system is unpressurised.
2. Then close shut-off valve ahead of pressure transducer.
3. Slowly loosen the drainage and/or air vent screw.
4. Before finally removing the screw, wait until no medium is leaking out.
5. To clean, remove the closure plug at the end of the siphon pipe.
6. After pushing through, cleaning or blowing through, fill the siphon pipe with distilled water again.
14.1 Inspection periods

Loos International requires the device to be function tested every month.
14.2 Running the pressure limiter test

14.2.1 Steam boiler
Systems with LBC boiler control:
Systems without LBC boiler control
Read the Operating Instructions
Operate the burner control switch on the switchgear cabinet in the position
"Limiter test". Hold down the burner control switch and observe the boiler
pressure manometer until the boiler switches to Fault.
If there is no fault shut-off before the maximum permitted operating pressure is reached (marked by the red line on the
manometer), the boiler should be taken out of service immediately and the cause of the problem determined.
If, during the pressure limiter test, the pressure safeguard valve is tripped, make sure that the operating pressure of the
boiler falls briefly at least 15% below the trip pressure of the pressure safeguard valve (e.g. by briefly reducing the firing
Page 7 of 8
Pressure transducer
I003
Version 5 (05/05)
output), so that the pressure safeguard valve can close again completely and the pressure limiter releases the control again.
If the pressure safeguard valve is tripped before the firing is switched off, this may be caused by faults that are explained in
the chapter "Measures in the event of unusual observations and operating faults".
repaired.
14.2.2 Hot water boiler

5
4
1 = Pressure indicator (with test unit)
2 = Manostat tube
3 = Maximum pressure monitoring DSH
4 = Minimum pressure monitoring DSL
(if attached to manostat tube)
BAR
5 = Shut-off valve (secured against

unintentional closure)
6 = Limit switch
7 = Closure screw
Figure 3: Testing the pressure limiter

Before the start of the test, the shut-off valve (5) must be closed. The shut-off valve (5) is secured by a limit switch (6) to
prevent accidental closure. If the shut-off valve (5) is closed, the limit switch (6) triggers a boiler fault alarm.
After this, the screw plug (7) must be removed. The manostat pipe (2) must be subjected to external pressure (nitrogen,
water, e.g. by means of a hand pump). When the pressure rises, the maximum pressure monitoring (3) can be tested, and
when the pressure is released, the minimum pressure monitoring (4) can be tested.
Since, after the closure of the shut-off valve (5), the limit switch (6) triggered a boiler fault alarm, the limit switch (6) must be
bridged before the test by a key-operated push button at the control cabinet for the duration of the test (bridging possible for
max. 3 minutes). After this, the boiler control can be unlocked to test the trigger of a boiler fault by the pressure transducer .
If there is a second pressure transducer in each case at the manostat pipe (2) for maximum pressure monitoring (3) or
minimum pressure monitoring (4) (optional), then, in each case, a key-operated push button must be operated at the control
cabinet for the alternating testing of pressure transducer 1 and 2.
After the test has been carried out, the screw plug (7) must be closed and then the shut-off valve (5) opened.
Caution! The pressure limiter test must not be carried out under any circumstances with the forward and return
flow shut-off valves closed by means of a pressure rise through the supply of heat via the burner. With burner
operation, a through flow through the boiler must be ensured.
To order or inquire about replacement parts, please use the special Ordering/Inquiries form, L006 After Sales Services
which is to be found in File L (Forms).
Page 8 of 8
73018490 5.05 Fx/ivd
Elster GmbH
Steinern Strae 19-21
D-55252 Mainz-Kastel
D
Quantometer QA, QAe
DK
GR
TR
CZ
PL
RUS
www.elster.com
GB
Quantometers
QA, QAe
NL
Dbitmtre QA, QAe
Quantometers
QA, QAe
Misuratori di portata
QA, QAe
Cuantmetros
QA, QAe
Instrucciones de
Betriebsanleitung
Instructions de service Bedieningsvoorschrift
Istruzioni duso
Bitte lesen und aufbewahren
Please read and keep in a safe

place
A lire attentivement et con- Lezen en goed bewaren a.u.b.

server
Si prega di leggere e conser- utilizacin

vare
Se ruega que las lean y conserven
Zeichenerklrung
, , , = Ttigkeit
= Hinweis
Explanation of symbols
, , , = Action
= Instruction
Lgendes
, , , = action
= remarque
Legenda
, , , = werkzaamheden
= aanwijzing
Spiegazione dei simboli

, , , = Operazione
= Avvertenza
Explicacin de smbolos
, , , = Actividad
= Indicacin
Alle in dieser Betriebsanleitung

aufgefhrten Ttigkeiten drfen
nur von autorisiertem Fachpersonal ausgefhrt werden!
All the work set out in these operating instructions may only be
completed by authorised trained
personnel!
Toutes les actions mentionnes

dans les prsentes instructions
de service doivent tre excutes par des spcialistes forms
et autoriss uniquement !
Alle in deze bedrijfshandleiding

vermelde werkzaamheden mogen alleen door technici worden
uitgevoerd!
Tutte le operazioni indicate nelle

presenti istruzioni duso devono
essere eseguite soltanto dal
preposto esperto autorizzato.
Todas las actividades indicadas

en estas Instrucciones de utilizacin, slo deben realizarse por
una persona formada y autorizada!
WARNUNG! Unsachgemer Einbau, Einstellung, Vernderung,

Bedienung oder Wartung kann
Verletzungen oder Sachschden
verursachen.
Anleitung vor dem Gebrauch lesen.
Dieses Gert muss nach den geltenden Vorschriften installiert werden.
WARNING! Incorrect installation,

adjustment, modification, operation or maintenance may cause injury or material damage.
Read the instructions before use.
This unit must be installed in accordance with the regulations in
force.
ATTENTION ! Un montage, un
rglage, une modification, une utilisation ou un entretien inadapts
risquent dengendrer des dommages matriels ou corporels.
Lire les instructions avant utilisation.
Cet appareil doit tre install en respectant les rglements en vigueur.
WAARSCHUWING! Ondeskundige inbouw, instelling, wijziging, bediening of onderhoudswerkzaamheden kunnen persoonlijk letsel of
materile schade veroorzaken.
Aanwijzingen voor het gebruik lezen. Dit apparaat moet overeenkomstig de geldende regels worden genstalleerd.
ATTENZIONE! Se montaggio,
regolazione, modifica, utilizzo
o manutenzione non vengono
eseguiti correttamente, possono
verificarsi infortuni o danni.
Si prega di leggere le istruzioni prima di utilizzare il prodotto che dovr venire installato in base alle normative vigenti.
ADVERTENCIA! La instalacin,
ajuste, modificacin, manejo o mantenimiento incorrecto puede ocasionar daos personales o materiales.
Leer las instrucciones antes de
usar. Este dispositivo debe ser
instalado observando las normativas en vigor.
Konformittserklrung
Declaration of
conformity
Dclaration de
conformit
Verklaring van
overeenstemming
Dichiarazione di
conformit
Declaracin de
conformidad
We, the manufacturer, hereby declare that the products QA, marked
with product identification CE 0085,
II 2G c IIC Tamb. + 70 C, and
QAe, marked with product ID No.
CE 0085BM0186, comply with the
essential requirements of the following Directives:
QA, QAe: 97/23/EC,
QA:
94/9/EC.
The relevant products correspond to
the type tested by the notified body
0085.
Comprehensive quality assurance
is guaranteed by a certified Quality System pursuant to DIN EN ISO
9001:2000 according to annex III,
module D of Directive 97/23/EC.
Elster GmbH, Mainz-Kastel
En tant que fabricant, nous dclarons que les produits QA, identifis
par lidentification de produit CE
0085,
II 2G c IIC Tamb. + 70
C, et QAe, identifis par le numro
de produit CE 0085BM0186, rpondent aux exigences essentielles des
directives suivantes :
QA, QAe: 97/23/CE,
QA:
94/9/CE.
Les produits dsigns en consquence sont conformes au type
prouv lorganisme notifi 0085.
Une assurance de la qualit complte est garantie par un systme
qualit certifi selon DIN EN ISO
9001:2000, conformment lannexe III, module D, de la directive
97/23/CE.
Wij verklaren als fabrikant dat de

producten QA, gemerkt met het
product-identificatie CE 0085,
II 2G c IIC Tamb. + 70 C, en QAe,
gemerkt met het product-identificatienummer CE 0085BM0186, aan
de fundamentele voorschriften van
de volgende richtlijnen voldoen:
QA, QAe: 97/23/EG,
QA:
94/9/EG.
De overeenkomstig gekenmerkte
producten stemmen overeen met
het door de aangewezen instantie
0085 gecontroleerde type.
Een uitgebreide kwaliteitsborging
is gegarandeerd door een gecertificeerd kwaliteitsborgingssysteem
conform DIN EN ISO 9001:2000
overeenkomstig bijlage III, moduul D
van de richtlijn 97/23/EG.
Dichiariamo in qualit di produttori

che i prodotti QA, contrassegnati
con lidentificazione del prodotto
CE 0085,
II 2G c IIC Tamb. +
70 C, e QAe, contrassegnati con il
numero di identificazione del prodotto CE 0085BM0186, rispondono ai
requisiti essenziali posti dalle direttive seguenti:
QA, QAe: 97/23/CE,
QA:
94/9/CE.
I prodotti con tale contrassegno corrispondono al tipo esaminato dallorganismo notificato 0085.
La totale sicurezza della qualit
garantita da un sistema certificato
di management della qualit ai sensi
della DIN EN ISO 9001:2000, in base allappendice III, modulo D della
direttiva 97/23/CE.
Nosotros, el fabricante, declaramos

que los productos QA identificados
por la identificacin de producto CE
0085,
II 2G c IIC Tamb. + 70
C y QAe identificados por el No ID
de producto CE 0085BM0186 cumplen los requisitos bsicos de las
siguientes Directivas:
QA, QAe: 97/23/CE,
QA:
94/9/CE.
Los productos correspondientemente marcados coinciden con el
modelo constructivo ensayado en el
Organismo Notificado 0085.
El exhaustivo control de calidad est
garantizado por un sistema de gestin de calidad, certificado conforme
a la norma DIN EN ISO 9001:2000
segn el Anexo III, Mdulo D de la
Directiva 97/23/CE.
Wir erklren als Hersteller, dass die

Produkte QA, gekennzeichnet mit der
Produkt-Kennzeichnung CE 0085,
II 2G c IIC Tamb. + 70 C, und
QAe, gekennzeichnet mit der Produkt-ID-Nr. CE 0085BM0186, die
grundlegenden Anforderungen folgender Richtlinien erfllen:
QA, QAe: 97/23/EG,
QA:
94/9/EG.
Die entsprechend bezeichneten
Produkte stimmen berein mit den
bei der zugelassenen Stelle 0085
geprften Baumustern.
Eine umfassende Qualittssicherung
ist gewhrleistet durch ein zertifiziertes
Qualittsmanagementsystem
nach DIN EN ISO 9001:2000, gem Anhang III, Modul D der Richtlinie 97/23/EG.
-1-
QA
Das Quantometer QA ist fr den Betrieb in einem explosionsgefhrdeten Bereich der Kategorie 2 (Zone 1)
vorgesehen.
=
Spezifische Kennzeichnung fr den
Explosionsschutz.
II = Gertegruppe fr allgemeine
Industrie, alle brennbaren Gase und
Dmpfe.
2G = Gertekategorie fr explosionsfhige Gase, Dmpfe und Nebel.
c = Zndschutzart: Konstruktive
Sicherheit.
IIC = Explosionsgruppe: Art des
explosionsgefhrdeten Bereiches:
Alle Gase.
Tamb. + 70 C = Umgebungstemperatur.
Explosionsgefahr!
Elektrische
Anlage hinsichtlich der besonderen
Bestimmungen des elektrischen
Explosionsschutzes berprfen.
Keine versteckten Zndquellen in
den explosionsgefhrdeten Bereich, wie z. B. Taschenrechner,
Taschenlampen, batteriebetriebene
Messgerte usw., mitfhren.
Bei Arbeiten an elektrischen Anlagen in explosionsgefhrdeten
Bereichen drfen nur bauartzugelassene elektrische Betriebsmittel
eingesetzt werden. Spezialwerkzeuge fr den explosionsgefhrdeten Bereich benutzen.
QAe
Achtung! Das Quantometer QAe ist
nicht fr den Betrieb in explosionsgefhrdeten Bereichen vorgesehen.
QA, QAe
Zum Messen von Erdgas, Stadtgas,
Luft oder inerten Gasen, QAe auch
zum Messen des Momentandurchflusses.
Max. Eingangsdruck pemax
QA/QAe..-40: 4 bar fr Gas
und Luft,
QA/QAe..-160: 16 bar fr Inertgase und Luft, QA/QAe..Z auch
fr Gas.
Umgebungstemperatur:
QA: -10 bis +60 C,
QAe: 0 bis +50 C.
Volumenstrom Q siehe Typenschild.
Schutzart QA: IP 52
Schutzart QAe: IP 44
QA
QA
Quantometer QA is designed for op- Le dbitmtre QA est prvu pour
eration in Category 2 (zone 1) explo- tre utilis dans une zone risque
sion-hazard areas.
dexplosion 1 (catgorie 2).
=
Specific marking of explosion protection.
II = Equipment group for general
industries, all flammable gases and
vapours.
2G = Equipment category for explosive gases, vapours and hazes.
c = Type of ignition protection:
Constructional safety.
IIC = Explosion group: Type of explosion-hazard area: All gases.
Tamb. + 70 C = Ambient temperature.
=
Marquage spcifique de protection
contre les explosions.
II = Groupe dappareils pour lindustrie en gnral, tous les gaz et
vapeurs inflammables.
2G = Catgorie dappareils pour les
gaz, vapeurs et brouillards explosifs.
c = Type de protection : scurit
constructive.
IIC = Groupe dexplosion : type de
zone risque dexplosion : tous gaz.
Tamb. + 70 C =Temprature ambiante.
Risk of explosion! Check that

the electrical system complies with
the special explosion protection requirements.
Do not carry any possible source of
ignition such as pocket calculators,
torches, battery-operated meters,
etc. in an explosion-hazard area.
When working on electrical equipment in an explosion-hazard area,
only design-approved electrical
operating equipment may be used.
Use special tools for explosionhazard areas.
Risque dexplosion ! Vrifier linstallation lectrique pour la conformit avec les prescriptions particulires en matire de protection
contre les explosions.
Ne pas emporter des sources dallumage non-apparentes dans les
zones risque dexplosion, comme
par exemple des calculatrices de
poche, des lampes de poche, des
appareils de mesure batterie, etc.
En cas dintervention sur les installations lectriques dans les zones
risque dexplosion, il convient dutiliser uniquement des appareillages
lectriques homologus. Utiliser
des outils spciaux pour les zones
risque dexplosion.
QAe
Caution! Quantometer QAe is not
designed for operation in explosionhazard areas.
QA, QAe
For measuring natural gas, town
gas, air or inert gases, QAe also
suitable for measuring the current
throughput.
Max. inlet pressure pemax
QA/QAe..-40: 4 bar for gas
and air,
QA/QAe..-160: 16 bar for inert
gases and air, QA/QAe..Z also
for gas.
QA: -10 to +60C,
QAe: 0 to +50C.
Flow rate Q see type label.
Enclosure QA: IP 52
Enclosure QAe: IP 44
QAe
Attention ! Le dbitmtre QAe nest
pas prvu pour tre utilis dans des
zones risque dexplosion.
QA, QAe
Pour mesurer les dbits de gaz naturel, gaz de ville, air ou gaz inertes,
QAe permet galement de mesurer
le dbit instantan.
Pression dentre maxi. pemax
QA/QAe..-40 : 4 bar pour gaz et
air,
QA/QAe..-160 : 16 bar pour gaz
inertes et air, QA/QAe..Z galement pour gaz.
Temprature ambiante :
QA : -10 +60 C,
QAe : 0 +50 C.
Dbit Q voir la plaque signaltique.
Indice de protection QA : IP 52
Indice de protection QAe : IP 44
-2-
QA
QA
QA
De quantometer QA is bedoeld om Il misuratore di portata QA adat- El cuantmetro QA est previsto pate worden gebruikt op plaatsen waar to allutilizzo in aree a pericolo di ra el funcionamiento en atmsferas
explosiegevaar kan heersen (cate- esplosione rientranti nella categoria potencialmente explosivas de la cagorie 2, zone 1).
tegora 2 (zona 1).
2 (zona 1).
=
Specifiek kenteken ter bescherming
tegen explosie.
II = Apparatengroep voor de algemene industrie, alle brandbare gassen en dampen.
2G = Apparatuurcategorie voor explosieve gassen, dampen en nevels.
c = Type beveiliging: Constructieve
veiligheid.
IIC = Explosiegroep: type plaats
waar explosiegevaar kan heersen:
alle gassen.
Tamb. + 70 C = Omgevingstemperatuur.
Explosiegevaar! Elektrische installatie m.b.t. de bijzondere bepalingen van de elektrische bescherming tegen explosie controleren.
Geen
verborgen
ontstekingsoorzaken op plaatsen waar explosiegevaar kan heersen, zoals
bijvoorbeeld pocket calculators,
zaklantaarns, op batterijen werkende meetapparatuur enz., meevoeren.
Bij werkzaamheden aan elektrische installaties op plaatsen waar
explosiegevaar kan heersen mogen alleen officieel goedgekeurde
elektrische hulpmiddelen worden
toegepast. Gebruik speciaal gereedschap voor de plaats waar explosiegevaar kan heersen.
QAe
Attentie! De quantometer QAe is
niet bedoeld om te worden gebruikt
op plaatsen waar explosiegevaar
kan heersen.
=
Marcatura specifica relativa alla protezione contro lesplosione.
II = Gruppo di apparecchi per lindustria in generale, per gas e vapori
infiammabili di ogni tipo.
2G = Categoria di apparecchi per
gas, vapori e nebbie a rischio di
esplosione.
c = Tipo di protezione: sicurezza
costruttiva.
IIC = Gruppo esplosione: tipo di
area a pericolo di esplosione: tutti
i gas.
Tamb. + 70 C = Temperatura ambiente.
Pericolo desplosione! Controllare se limpianto elettrico risponde alle norme speciali relative alla
protezione elettrica contro le esplosioni.
Non portare nella zona a pericolo
di esplosione fonti di potenziali accensioni, come ad es. calcolatrici
tascabili, torce elettriche, strumenti
di misura a batterie, ecc.
Quando si lavora su impianti elettrici in zone a pericolo di esplosione,
si possono utilizzare solo dispositivi
elettrici di tipo omologato. Usare
utensili speciali per zone a pericolo
di esplosione.
QAe
Attenzione! Il misuratore di portata
QAe non adatto allutilizzo in aree
a pericolo di esplosione.
QA, QAe
Per misurare portate di metano, gas
di citt, aria o gas inerti, QAe anche
QA, QAe
per misurare la portata istantanea.
Voor het meten van aardgas, stads- Pressione di entrata max. pemax
gas, lucht of inerte gassen, QAe ook
QA/QAe..-40: 4 bar per gas e
voor het meten van de momentele
aria,
doorstroming.
QA/QAe..-160: 16 bar per gas
Max. inlaatdruk pemax
inerti e aria, QA/QAe..Z anche
per gas.
QA/QAe-40:
4 bar voor gas en
Temperatura ambiente:
lucht,
QA: da -10 a +60 C,
QA/QAe..-160: 16 bar voor inertQAe: da 0 a +50 C.
gassen en lucht, QA/QAe..Z ook
Portata Q vedi targhetta dati.
voor gas.
Tipo di protezione per QA: IP 52
Omgevingstemperatuur:
Tipo di protezione per QAe: IP 44
QA: -10 tot +60C,
QAe: 0 tot +50C.
Volumestroom Q zie typeplaatje.
Beschermingsklasse QA: IP 52
Beschermingsklasse QAe: IP 44
=
Marcado especfico para la proteccin antideflagrante.
II = Grupo de aparatos para la industria en general, todos los gases
y vapores combustibles.
2G = Categora de aparatos para
gases, vapores y nieblas capaces
de explosionar.
c = Tipo de proteccin: Seguridad
constructiva.
IIC = Grupo de explosin:Tipo de
zona con riesgo de explosin: Todos los gases.
Tamb. + 70 C = Temperatura ambiente.
Peligro de explosin! Comprobar la instalacin elctrica por lo
que respecta a las normas especiales de la proteccin elctrica
antideflagrante.
No introducir en la zona con riesgo
de explosin ninguna posible fuente oculta de encendido, como p. ej.
calculadoras de bolsillo, linternas,
aparatos de medicin accionados
por bateras etc.
Al realizar trabajos en las instalaciones elctricas de las zonas con
riesgo de explosin, slo se deben
emplear equipos elctricos homologados para estas zonas. Utilizar
herramientas especiales para zonas con riesgo de explosin.
QAe
Atencin! El cuantmetro QAe no
est previsto para el funcionamiento
en atmsferas potencialmente explosivas.
QA, QAe
Para medir volumen de gas natural,
gas ciudad, aire o gases inertes, el
QAe para medir tambin el caudal
momentneo.
Presin de entrada mx. pemax
QA/QAe..-40: 4 bar para gas y
aire,
QA/QAe..-160: 16 bar para gases inertes y aire, los QA/QAe..Z
tambin para gas.
Temperatura ambiente:
QA: -10 hasta +60 C,
QAe: 0 hasta +50 C.
Caudal Q vase placa de caractersticas.
Grado de proteccin de QA:
IP 52
Grado de proteccin de QAe:
IP 44
Prfen
Lieferumfang QA...G I, QAe...G I
a = Quantometer
b = berwurfverschraubungen
c = Dichtringe
d
E1
E200
QA...G I, mechanischer Zhlwerkkopf:

d = 2 Stecker fr Impulsgeber
Lieferumfang QA..Z, QAe..Z

a = Quantometer
b = Sechskantschrauben und Muttern
Vrifier
Controleren
Verificare
Comprobar
Delivery for QA...G I, QAe...G I

a = Quantometer
b = Union nut fittings
c = Gaskets
Contenu de la livraison pour

QA...G I, QAe...G I
a = Dbitmtre
b = Raccords filets
c = Joints dtanchit
Leveringsomvang QA...G I,
QAe...G I:
a = Quantometer
b = Wartels
c = O-ringen
Corredo di fornitura per

QA...G I, QAe...G I
a = Misuratore di portata
b = Connessioni mediante riduzioni
filettate
c = Guarnizioni
Componentes del suministro

para QA...G I, QAe...G I
a = cuantmetro
b = uniones roscadas
c = juntas tricas
QA...G I, totalisateur mcanique :

d = 2 connecteurs pour transmetteur dimpulsions
QA...G I, mechanisch telwerk:

d = 2e stekker voor impulsgever
QA...G I, mechanical counter head:

d = 2 plugs for pulse generator
c
QAe...G I, elektronischer Zhlwerkkopf:
d = 1 Stecker fr Impulsgeber
Als Option fr QAe...G I lieferbar:
e = M-Bus
Testing
QAe...G I, electronic counter head:

d = 1 plug for pulse generator
Available as an option for QAe...G I:
e = M-Bus
QAe...G I, totalisateur lectronique : QAe...G I, elektronisch telwerk:

d = 1 connecteur pour transmet- d = 1 stekker voor impulsgever
teur dimpulsions
Als optie voor QAe...G I leverbaar:
En option pour QAe...G I :
e = M-bus
e = M-Bus
QAe...G I, testa totalizzatrice elet- QAe...G I, totalizador del contador

tronica:
electrnico:
d = 1 connettore per trasmettitore d = 1 conector para transmisor de
di impulsi
impulsos
Opzionale per QAe...G I:
Suministrable como opcin para el
e = M-Bus
QAe...G I:
e = M-Bus
Delivery for QA..Z, QAe..Z

a = Quantometer
b = Hexagon screws and nuts
Contenu de la livraison pour

QA..Z, QAe..Z
a = Dbitmtre
b = Vis hexagonales et crous
Leveringsomvang QA..Z, QAe..Z:

a = Quantometer
b = Zeskantige schroeven en moeren
Corredo di fornitura per

QA..Z, QAe..Z
a = Misuratore di portata
b = Viti a testa esagonale e dadi
QA..Z, totalisateur mcanique :

c = 2 connecteurs pour transmetteur dimpulsions
QA..Z, mechanisch telwerk:

c = 2e stekker voor impulsgever
QA..Z, testa totalizzatrice meccanica:

QA..Z, totalizador del contador mec = 2 connettori per trasmettitore di cnico:
impulsi
c = 2 conectores para transmisores de impulsos
E200
E1
E200
QA..Z, mechanical counter head:

c = 2 plugs for pulse generator
QA..Z, mechanischer Zhlwerkkopf:

c = 2 Stecker fr Impulsgeber
QA...G I, totalizador del contador

mecnico:
d = 2 conectores para transmisores de impulsos
QA...G I, testa totalizzatrice meccanica:

d = 2 connettori per trasmettitore di
impulsi
Componentes del suministro

para QA..Z, QAe..Z
a = cuantmetro
b = tornillos hexagonales y tuercas
QAe..Z, elektronischer Zhlwerkkopf:

c = 1 Stecker fr Impulsgeber
Als Option fr QAe..Z lieferbar:
d = M-Bus
QAe..Z, electronic counter head:

c = 1 plug for pulse generator
Available as an option for QAe..Z:
d = M-Bus
c
E200
QAe..Z, totalisateur lectronique :

QAe..Z, elektronische telwerk:
c = 1 connecteur pour transmet- c = 1 stekker voor impulsgever
teur dimpulsions
Als optie voor QAe..Z leverbaar:
En option pour QAe..Z :
d = M-bus
d = M-Bus
-3-
QAe..Z, testa totalizzatrice elettronica:

3 = 1 connettore per trasmettitore
di impulsi
Opzionale per QAe..Z:
4 = M-Bus
QAe..Z, totalizador del contador

electrnico:
3 = 1 conector para transmisor de
impulsos
Suministrable como opcin para el
QAe..Z:
4 = M-Bus
Einbauen
Installation
Explosionsgefahr! Elektrische
Anlage hinsichtlich der besonderen Bestimmungen des
elektrischen Explosionsschutzes
berprfen.
Bei Arbeiten an elektrischen Anlagen in explosionsgefhrdeten Bereichen: Nur bauartzugelassene
elektrische Betriebsmittel einsetzen. Elektrostatische Aufladung
vermeiden beispielsweise durch
das Reinigen der Zhlwerkhaube
mit einem trockenen Tuch.

the electrical system complies
with the special explosion protection requirements.
When working on electrical equipment in an explosion-hazard area:
Only design-approved electrical
Avoid static electricity charge, e.g.
by cleaning the counter cover with
a dry cloth.
Einbaulage senkrecht oder waagerecht, nicht ber Kopf.

Bei Gasen, die zur Kondensatbildung neigen, den QA/QAe
in Durchflussrichtung von oben
nach unten einsetzen Kondensatablauf in der Rohrleitung verwenden!
Wird das Quantometer in Gewindeausfhrung zur Mengenregelung verwendet (E200 als
Impulsausgang), QA/QAe...G I
nur waagerecht mit Zhlwerkkopf
oben einbauen.
Wir empfehlen einen Filter einzubauen, wenn der Gasstrom nicht
frei von Fremdkrpern und Staub
ist.
Bei Neuanlagen empfehlen wir
ein Sieb (Maschenweite 0,5 mm)
direkt vor den Zhler einzusetzen,
um diesen vor Fremdkrpern, wie
z. B. Metallspnen, zu schtzen.
Das Sieb sollte nach sptestens
4 Wochen entfernt werden.
Bei Kondensat oder Verschmutzungen im Gasstrom das Quantometer nicht am tiefsten Punkt
der Rohrleitung einbauen.
Das Quantometer in eine gerade
Rohrleitung einbauen.
Einlaufstrecke = 3 x DN,
Auslaufstrecke = 2 x DN.
Rohrleitung mit gleicher Nennweite verwenden.
Die Auslaufstrecke hinter dem
Quantometer darf keine Verengungen aufweisen, damit kein
Strmungsstau entstehen kann.
Als Dichtungen knnen alle zugelassenen Arten von Flachdichtungen eingesetzt werden.
Das Quantometer sto- und impulsfrei betreiben.
Gaszufuhr absperren.
QA, QAe
3 x DN
2 x DN
Fitting position vertical or horizontal, not upside down.

Install the QA/QAe in the flow
direction from top to bottom for
gases that tend to condensate
use a condensate drain in the
pipeline.
If a threaded version quantometer
is used for flow control purposes
(E200 as a pulse output), only
install the QA/QAe...G I in a horizontal position with the counter
head at the top.
If the flowing gas is contaminated
by foreign bodies and dust, a filter
should be installed.
When designing new systems,
it is recommended to install a
strainer (mesh size 0.5 mm) immediately upstream of the meter
to protect it from foreign bodies
such as metal chips. The strainer
should be removed after 4 weeks
at the latest.
If the flowing gas is contaminated
by condensation or dirt, the quantometer should not be installed at
the lowest point of the pipe.
Install the quantometer in a
straight pipeline.
Inlet section = 3 x DN,
outlet section = 2 x DN.
Use a pipeline with the same
nominal dimensions.
The pipe downstream of the
quantometer must not have any
restriction point which could
cause the flow to back up.
All approved flat seal types may
be used.
Operate the quantometer in a
shock-free and pulse-free environment.
Shut off the gas supply.
Montage
Inbouwen
Risque dexplosion ! Vrifier

linstallation lectrique pour la
conformit avec les prescriptions
particulires en matire de protection contre les explosions.
risque dexplosion : utiliser uniquement des appareillages lectriques
homologus. Eviter une charge
lectrostatique en nettoyant par
exemple le capot du compteur
laide dun chiffon sec.
Position de montage verticale ou
horizontale, pas lenvers.
Pour les gaz qui ont tendance
crer de la condensation, installer
le QA/QAe dans le sens de passage du fluide de haut en bas
installer un purgeur automatique
dans la tuyauterie.
Si le dbitmtre construction
taraude est utilis pour rguler
le dbit (E200 comme sortie
impulsions), toujours installer le
QA/QAe...G I horizontalement,
totalisateur en haut.
Nous recommandons de monter
un filtre si le flux de gaz nest pas
exempt de corps trangers et de
poussire.
Pour des installations neuves,
nous recommandons linstallation dun tamis (largeur de maille
0,5 mm) directement en amont
du compteur afin de protger celui-ci contre les corps trangers
comme par ex. les copeaux mtalliques. Le tamis doit tre retir
au bout de 4 semaines au plus
tard.
En cas de condensation ou dimpurets dans le flux de gaz, ne
pas monter le dbitmtre au niveau le plus bas de la conduite.
Monter le dbitmtre dans une
conduite droite.
Ligne dentre = 3 x DN,
ligne de dcharge = 2 x DN.
Utiliser une conduite ayant un diamtre nominal identique.
Le tuyau en aval du dbitmtre ne
doit prsenter aucun rtrcissement afin dviter une obstruction
de lcoulement.
Tous les types de joints plats
autoriss peuvent tre utiliss
comme joints dtanchit.
Faire fonctionner le dbitmtre
sans -coups ni impulsions.
Fermer lalimentation gaz.
Turbinenrad durch Anblasen auf Leichtgngigkeit berprfen.

Check that the turbine wheel is able to move easily by blowing on to the vanes.
Aprs soufflage, vrifier que la roue de turbine tourne librement.
Turbinewiel door aanblazen op lichte loop controleren.
Soffiando, controllare che la girante della turbina giri
liberamente.
Comprobar soplando que la turbina gira con facilidad.
-4-
Explosiegevaar!
Elektrische
installatie m.b.t. de bijzondere
bepalingen van de elektrische
bescherming tegen explosie controleren.
explosiegevaar kan heersen: Alleen officieel goedgekeurde elektrische hulpmiddelen inzetten.
Elektrostatische oplading voorkomen bijvoorbeeld door de
telwerkkop met een droog lapje
te reinigen.
Inbouwpositie verticaal of horizontaal, niet onderste boven.
Bij gassen, die tot condensvorming neigen, de QA/QAe in doorstroomrichting van boven naar
beneden inbouwen condensafvoer in de leiding gebruiken!
Wordt de quantometer in schroefdraaduitvoering voor de hoeveelheidsregeling gebruikt (E200 als
impulsuitgang), dan QA/QAe...G I
alleen horizontaal met telwerk boven inbouwen.
Wij raden u aan om een filter in te
bouwen wanneer de gasstroom
niet vrij van verontreiniging en stof
is.
Bij nieuwe installaties raden wij
u aan om een zeef (maaswijdte
0,5 mm) direct voor de gasmeter
aan te brengen om deze te beschermen tegen verontreiniging,
zoals bijvoorbeeld metalen spanen. De zeef moet uiterlijk na 4
weken worden verwijderd.
Bij condensatie of verontreiniging
in de gasstroom de quantometer
niet op het laagste punt van de
leiding inbouwen.
De quantometer in een rechte leiding inbouwen.
Inlooptraject = 3 x DN,
uitlooptraject = 2 x DN.
Leiding met dezelfde nominale
diameter gebruiken.
De leiding achter de quantometer
mag geen vernauwingen bezitten,
zodat er geen opstuwing kan ontstaan.
Als dichtingen kunnen alle goedgekeurde soorten platte dichtingen worden toegepast.
De quantometer stoot- en impulsvrij gebruiken.
Gastoevoer afsluiten.
Montaggio
Pericolo desplosione! Controllare se limpianto elettrico risponde alle norme speciali relative
alla protezione elettrica contro le
esplosioni.
Quando si lavora su impianti elettrici in zone a pericolo di esplosione: utilizzare solo dispositivi
elettrici di tipo omologato. Evitare
cariche elettrostatiche ad esempio pulendo il coperchio del totalizzatore con un panno asciutto.
Posizione di montaggio verticale
o orizzontale, non capovolta.
In caso di gas che tendono a
formare condensa, inserire il
QA/QAe nella direzione di flusso,
dallalto verso il basso utilizzare
lo scarico della condensa nella
tubatura!
Se si utilizza il misuratore di portata in versione filettata per regolare
la portata (E200 come uscita ad
impulsi), montare il QA/QAe...G I
solo in posizione orizzontale con
la testa totalizzatrice rivolta verso
lalto.
Consigliamo di montare un filtro
se il flusso di gas presenta impurit e polvere.
Negli impianti nuovi raccomandiamo di applicare un filtro a rete
(larghezza della maglia 0,5 mm)
subito prima del contatore, per
proteggerlo da impurit come ad
esempio trucioli di metallo. Il filtro
a rete dovrebbe essere rimosso
dopo 4 settimane al massimo.
In presenza di condensa o sporcizia nel flusso di gas non montare
il misuratore di portata nel punto
pi profondo della tubazione.
Montare il misuratore di portata in
una tubazione diritta.
Tratto di entrata = 3 x DN,
tratto di uscita = 2 x DN.
Utilizzare tubazioni con lo stesso
diametro nominale.
Affinch il flusso non ristagni, il
tubo a valle del misuratore di portata non deve presentare restringimenti.
Come guarnizioni si possono
utilizzare tutti i tipi di guarnizioni
piatte ammesse.
Azionare il misuratore di portata
senza scosse e senza impulsi.
Interrompere lalimentazione del
gas.
Montaje
antideflagrante.
Para realizar trabajos en las instalaciones elctricas de las zonas
con riesgo de explosin: Slo se
deben emplear equipos elctricos homologados. Evitar la carga
electroesttica, por ejemplo mediante la limpieza de la tapa del
contador con un pao seco.
Posicin de montaje horizontal o
vertical, pero no cabeza abajo.
En caso de gases con tendencia
a formar condensacin, instalar
el cuantmetro QA/QAe en el
sentido del flujo, de arriba hacia
abajo utilizar el purgador de
condensado en la tubera.
Si se utiliza el cuantmetro en su
versin con rosca para la regulacin
del caudal (E200 como salida de
impulsos), montar el QA/QAe...G I
slo horizontalmente, con el cabezal totalizador hacia arriba.
Recomendamos montar un filtro
cuando la corriente de gas no est
libre de cuerpos extraos y polvo.
En nuevas instalaciones recomendamos utilizar un tamiz (ancho de malla de 0,5 mm) directamente delante del contador para
proteger el mismo contra cuerpos extraos, como por ejemplo
virutas metlicas. El tamiz debera
quitarse al cabo de 4 semanas, a
ms tardar.
En caso de condensado o ensuciamiento en la corriente de gas,
el cuantmetro no deber montarse en el punto ms bajo de la
tubera.
Montar el cuantmetro en una
tubera recta.
Tramo de entrada = 3 x DN,
Tramo de salida = 2 x DN.
Utilizar tubera del mismo dimetro nominal.
El tubo aguas abajo del cuantmetro no debe tener ningn estrechamiento, para que no se puedan
formar retenciones del flujo.
Como juntas podrn utilizarse
todos los tipos de juntas planas
homologadas.
El cuantmetro deber funcionar
libre de golpes e impulsos.
Cortar el suministro de gas.
QA...G I, QAe...G I
QA..Z, QAe..Z
Dichtung konzentrisch ausrichten, damit sie nicht in das Rohrinnere hineinragt.

Align the seal concentrically so that it does not protrude into the
pipe.
Placer le joint dtanchit de faon concentrique afin quil ne
pntre pas lintrieur du tube.
Dichting centrisch uitlijnen zodat deze niet in het binnenste van
de leiding steekt.
Posizionare la guarnizione in modo concentrico, affinch non
sporga nella parte interna della tubazione.
La junta deber alinearse de forma concntrica para que no penetre en el interior del tubo.
Dichtung konzentrisch ausrichten, damit sie nicht in das Rohrinnere hineinragt.

Align the seal concentrically so that it does not protrude into the
pipe.
Placer le joint dtanchit de faon concentrique afin quil ne
pntre pas lintrieur du tube.
Dichting centrisch uitlijnen zodat deze niet in het binnenste van
de leiding steekt.
Posizionare la guarnizione in modo concentrico, affinch non
sporga nella parte interna della tubazione.
La junta deber alinearse de forma concntrica para que no penetre en el interior del tubo.
Gas-Magnetventile nur hinter

dem Quantometer anordnen.
Only install gas solenoid valves

downstream of the quantometer.
Placer les lectrovannes gaz en

aval du dbitmtre uniquement.
Gasmagneetkleppen alleen ach- Disporre le valvole elettromagne- Las vlvulas electromagnticas

ter de quantometer aanbrengen.
tiche per gas esclusivamente a
para gas slo debern disponervalle del misuratore di portata.
se detrs del cuantmetro.
M-Bus
M-Bus
M-Bus
M-bus
QAe
Kappe abziehen nicht nach oben aushebeln.

Prise off cap by pushing screwdriver downwards only.
Retirer le cache laide du tournevis en exerant une pression
vers le bas.
Kap lostrekken niet naar boven loswrikken.
Togliere la calotta, facendo leva con il cacciavite verso il basso e
non verso lalto.
Quitar la tapa, presionando para ello con el destornillador slo
hacia abajo.
-5-
M-Bus
M-Bus
Dichtheitsprfung
Tightness test
Vrifier ltanchit
Ausgang von QA, QAe mit Steck-
Close the outlet of QA, QAe with
Fermer la sortie du QA, QAe avec
scheibe schlieen oder das GasMagnetventil hinter dem Quantometer schlieen.
blanking plate or shut off the solenoid valve for gas downstream of
the quantometer.
QA...G I, QAe...G I
une plaque dobturation ou fermer llectrovanne gaz situe en

aval du dbitmtre.
Lektest
Controllo della tenuta
Uitgang van QA, QAe met steek- Chiudere luscita di QA, QAe con
schijf sluiten of de gasmagneetklep achter de quantometer sluiten.
Comprobar la
estanquidad
un tappo a innesto oppure chiu- Cerrar la salida del QA, QAe con una
dere la valvola elettromagnetica
brida ciega o cerrar la vlvula electroper gas a valle del misuratore di
magntica detrs del cuantmetro.
portata.
N2
1,5 x pe max
QA..Z, QAe..Z
N2
1,5 x pe max
Steckscheibe entfernen oder das
Remove blanking plate or open
Retirer la plaque dobturation ou
Steekschijf verwijderen of de gas- Rimuovere il tappo a innesto op- Quitar la brida ciega o abrir la vl-
In Betrieb nehmen
Commissioning
Mise en service
In bedrijf stellen
Gas-Magnetventil hinter
Quantometer ffnen.
dem
Achtung! Der Druck vor dem

Quantometer darf nur langsam
erhht werden.
Das Absperrorgan vor dem
Quantometer zuerst ffnen. Alle
Absperrorgane langsam ffnen.
Druckerhhung beim Befllen
oder Druckschwankungen am
QA/QAe: bis max. 350 mbar/s.
the solenoid valve for gas downstream of the quantometer.
Caution! The pressure upstream

of the quantometer may be increased only slightly.
ouvrir llectrovanne gaz situe en

aval du dbitmtre.
Attention ! En amont du dbitmtre, la pression doit tre augmente lentement.
magneetklep achter de quantometer openen.
Attentie! De druk voor de flowmeter mag slechts langzaam worden opgevoerd.
pure aprire la valvola elettromagnetica per gas a valle del misuratore di portata.
Messa in servizio
Attenzione! La pressione a monte
del misuratore di portata deve essere aumentata lentamente.
vula electromagntica detrs del

cuantmetro.
Puesta en servicio
Atencin! Incrementar la presin
de gas lentamente antes del cuantmetro.
Open the shut-off device up- Ouvrir tout dabord le robinet De stopkraan voor de quantome- Aprire per primo il dispositivo di Abrir primero el dispositivo de
stream of the quantometer first.
darrt situ en amont du dbitter eerst openen. Alle stopkranen
intercettazione a monte del micierre que est delante del cuanOpen all shut-off devices slowly.
mtre. Ouvrir tous les robinets
langzaam openen.
suratore di portata. Aprire lentatmetro. Abrir todos los dispositi Pressure increase when filldarrt lentement.
Druktoename bij het vullen
mente tutti i dispositivi di intervos de cierre lentamente.
ing or pressure fluctuations Augmentation de la pression
of drukschommelingen op
cettazione.
Aumento de la presin al lleon the QA/QAe: Up to max.
en cas de remplissage ou de
QA/QAe: tot max. 350 mbar/s.
Aumento della pressione dunar o al haber oscilaciones de
350 mbar/s.
fluctuations de pression au
rante lo riempimento o variapresin en el QA/QAe: hasta
niveau du QA/QAe : jusqu
zioni di pressione sul QA/QAe:
un mximo de 350 mbar/s.
350 mbar/s maxi.
fino a 350 mbar/s al massimo.
-6-
Anzeige
Indication
Affichage
QA
Das verbrauchte Betriebsvolumen wird am mechanischen
Zhlwerkkopf aufsummiert in
m3(b) angezeigt.
QAe
Das Display des elektronischen
Zhlwerkkopfes zeigt im Grundzustand summierend die verbrauchte Menge [m3 (b)].
Modus und Anzeigewerte wechseln in kurzen Zeitabstnden. Im
Modus Stichtag wird nicht 4
angezeigt: Die Anzeige wechselt
zwischen Stichtag und Stichtagsvolumen.
QA
The operating volume consumed
is indicated, totalised in m3(b), on
the mechanical counter head.
QAe
In default condition the display
on the counter head shows the
cumulative quantity consumed
[m3 (b)].
The mode number and its corresponding value alternate rapidly
on the display. In the Key date
mode, the display alternates
between key date and key-date
volume rather than the mode
number 4.
QA
Le volume consomm totalis est
affich sur le totalisateur mcanique en m3(b).
QAe
Lcran du totalisateur lectronique indique en mode initial le volume consomm totalis [m3 (b)].
Mode et valeur daffichage alterns intervalles courts. En mode
jour J, le 4 ne saffiche pas.
Affichage altern du jour J et du
volume au jour J.
Druckknopf bettigen, um nachfolgende Werte aufzurufen.

-1- Modus Grundzustand:
Stichtagswert [m3/a] zeigt den
Verbrauch bis zum letzten Stichtag an. Die Stichtagswertfunktion speichert einmal im Jahr (am
Stichtag) den Gesamtverbrauch.
Mit dieser Funktion kann zu jedem Zeitpunkt der Verbrauch im
aktuellen Jahr bestimmt werden,
z. B. Gesamtverbrauch ber alle
Jahre (Grundzustand): 309560 m3.
Stichtagswert (bis Ende des
letzten Jahres): 300000 m3, das
heit: In diesem Jahr wurden
9560 m3 verbraucht.
-2- Modus Hochauflsende Anzeige:
Hochauflsung des Gesamtverbrauchs [m3]. Drei Stellen hinter
dem Komma werden angezeigt.
-3- Modus Momentandurchfluss:
Momentandurchfluss [m3/h (b)].
Bei Rckwrtsfluss ndert sich
die Richtungsanzeige im Display
von + auf .
-4- Modus Stichtag:
Stichtagsdatum, gibt das Datum
an, an dem der Gesamtverbrauch
in den Stichtagswert eingespeichert wird (Grundeinstellung ab
Werk: 31.12.jj). Stichtag und
Stichtagsvolumen [m3/a] werden
wechselnd angezeigt. Sie knnen
auch per M-Bus ausgelesen werden.
-5- Modus Rckwrtsvolumen:
Hochauflsendes Rckwrtsvolumen in m3.
Um wieder in die Grundanzeige
zurckzuspringen:
Nach Modus 5 nochmals den
Druckknopf bettigen.
0085
II 2G c IIC Tamb.+ 70C
0 0 0 6 9 , 1 1 m3
Quantometer
QA xxxx-x
-1-
m3
309560 m3
+309560.167 m3
006,253 m3
31-12-04 m3
625,293 m3
Press the push-button to recall

the values stated below.
-1- Default mode:
Key-date value [m3/a] indicates
the consumption through to the
last key date. The key-date value
function stores the total consumption figures once per year
(on the key date). This function
allows you to determine the consumption in the current year at
any time, e.g. total consumption
over all years (normal indication):
309,560 m3. Key-date value
(through to the end of the last
year): 300,000 m3, i.e.: 9,560 m3
were consumed this year.
-2- High resolution display mode:
High resolution of the total consumption [m3]. Three places after
the decimal point are displayed.
-3- Current throughput mode:
Current throughput [m3/h (b)]. In
the case of reverse flow, the direction indicator on the display
changes from + to .
-4- Key date mode:
Key date indicates the date on
which the total consumption is
saved in the key-date value (exworks default setting: 31.12.YY).
Key date and key-date volume
[m3/a] are displayed alternately.
They can also be read out using
an M-Bus.
-5- Reverse flow volume mode:
High resolution of the reverse flow
volume in m3.
To return to the initial display:
Press the button again once
modus 5 has been displayed.
Aanduiding
QA
Het verbruikte arbeidsvolume
wordt door het mechanische telwerk opgeteld in m3(b) aangegeven.
QAe
Het display van het elektronische
telwerk wijst in de uitgangstoestand de totaal verbruikte hoeveelheid [m3 (b)] aan.
Modus en indicatie wisselen elkaar in korte tussenpozen af. In
de modus teldag wordt niet 4
aangegeven: de aanduiding wisselt tussen teldag en teldagvo Actionner le bouton-poussoir afin
lume.
de faire apparatre les valeurs suivantes.
Drukknop indrukken om de volgende waarden op te roepen.
-1- Mode initial :
La valeur au jour J [m3/a] indique
la consommation jusquau der- -1- Modus uitgangstoestand:
teldagwaarde [m3/a] geeft het
nier jour J. La fonction jour J mmorise le volume total consomm
verbruik tot de laatste teldag aan.
une fois par an (au jour J). Cette
De teldagfunctie slaat n keer
fonction permet de dfinir chaper jaar (op de teldag) het totale
que instant le volume consomm
verbruik op. Met deze functie kan
pour lanne en cours, par ex.
voor elk tijdstip het verbruik in het
le volume total consomm pour
actuele jaar worden bepaald, bijv.
toutes les annes (affichage inihet totaalverbruik over alle jaren
3
tial) : 309 560 m . Valeur au jour
(uitgangstoestand): 309560 m3.
J (jusqu la fin de lanne prcTeldagwaarde (tot het einde van
dente) : 300 000 m3, autrement
het laatste jaar): 300000 m3
dit : au cours de cette anne,
dat wil zeggen: in dit jaar is er
le volume consomm est de
9560 m3 verbruikt.
9 560 m3.
-2- Modus verfijnde indicatie:
Verfijnde indicatie van het to-2- Mode affichage haute rsolutale verbruik [m3]. Er worden drie
tion :
Volume total consomm haute
plaatsen achter de komma aan3
rsolution [m ]. Affichage de prgegeven.
-3- Modus momentele doorstrocision trois dcimales.
ming:
-3- Mode dbit instantan :
Momentele doorstroming [m3/h (b)].
Dbit instantan [m3/h (b)]. En
flux inverse, laffichage de direcBij terugstroming verandert de
tion passe de + sur lcran.
richtingsaanduiding op het dis-4- Mode jour J :
play van + in .
Date du jour J : indique la date -4- Modus teldag:
laquelle le volume total consomTeldagdatum geeft de datum aan
m est mmoris (rglage de bawaarop het totaalverbruik in de
se en usine : 31.12.aa). Affichage
teldagwaarde wordt opgeslagen
altern du jour J et du volume au
(standaard configuratie af fabriek:
jour J [m3/a]. Ils peuvent gale31.12.jj). Teldag en teldagvolume
[m3/a] worden afwisselend aanment tre visualiss par M-Bus.
-5- Mode volume inverse :
gegeven. Dit kan ook via de MVolume inverse haute rsolution
bus worden uitgelezen.
3
en m .
-5- Modus terugstroomvolume:
Verfijnde indicatie van het terugstroomvolume in m3.
Pour revenir laffichage de dpart :
Aprs le mode 5, actionner de Om weer in naar de uitgangsindinouveau le bouton-poussoir.
catie terug te keren:
Na modus 5 nogmaals op de
knop drukken.
-7-
Indicazione
Indicacin
QA
Il volume consumato durante
lesercizio indicato sulla testa
totalizzatrice meccanica quale
totale in m3(b) (m3 di lavoro).
QAe
Nello stato normale il display posto sopra al totalizzatore elettronico indica la somma della quantit
consumata in [m3 (b)].
La modalit e il valore visualizzato
variano a intervalli brevi. In modalit giorno di riferimento non si
legge 4: il display alterna il giorno di riferimento e il volume del
giorno di riferimento.
QA
El volumen vehiculado se va sumando y aparece indicado en
m3(b) en el totalizador del contador mecnico.
QAe
La pantalla del totalizador del
contador electrnico muestra
sumando en condiciones de
operacin la cantidad consumida
[m3 (b)].
El modo y los valores de visualizacin se alternan en cortos intervalos de tiempo. En el modo de da
de vencimiento no se muestra 4:
La visualizacin alterna entre el da
de vencimiento y su volumen.
Azionare il pulsante per richiamare i valori successivi.

Accionar el pulsador para recuperar los siguientes valores.
-1- Modalit Stato normale:
il valore del giorno di riferimento -1- Modo condiciones de operacin:
[m3/a] indica il consumo fino alEl valor del da de vencimiento
[m3/a] indica el consumo hasta
lultimo giorno di riferimento. La
funzione del valore del giorno di
el da de vencimiento indicado.
riferimento memorizza una volta
La funcin da de vencimiento
allanno (nel giorno di riferimento)
almacena una vez al ao el conil consumo totale. Con questa
sumo total (hasta el da de venfunzione si pu determinare in
cimiento). Con esta funcin, en
ogni momento il consumo nellantodo momento se puede determino in corso, per esempio il consunar el consumo en el ao actual,
mo totale per tutti gli anni (stato
por ejemplo, el consumo total a lo
normale): 309560 m3. Valore del
largo de todos los aos (en condiciones de operacin): 309560 m3.
giorno di riferimento (alla fine dellanno trascorso): 300000 m3, di
Valor hasta el da de vencimiento (hasta finales del ltimo ao):
conseguenza: questanno si so300000 m3, es decir, en este ao
no consumati 9560 m3.
-2- Modalit Indicatore ad alta dese han consumido 9560 m3.
finizione:
-2- Modo visualizacin de alta realta definizione del consumo tosolucin:
tale [m3]. Si visualizzano tre cifre
Alta resolucin del consumo total
[m3] en las decenas, con tres dedopo la virgola.
-3- Modalit Portata istantanea:
cimales.
portata istantanea [m3/h (b)]. in -3- Modo caudal momentneo:
Caudal momentneo [m3/h (b)].
caso di flusso inverso, sul display
cambia lindicazione della direzioEn caso de caudal de retorno, la
ne da + a .
visualizacin de la direccin cam-4- Modalit Giorno di riferimento:
bia en la pantalla de + a .
la data del giorno di riferimento -4- Modo da de vencimiento:
quella in cui stato memorizzato
La fecha del da de vencimiento
il consumo totale nel valore del
indica la fecha en la cual se algiorno di riferimento (impostaziomacena el consumo total hasta
ne di base di fabbrica: 31/12/aa).
el da de vencimiento (ajuste bIl giorno di riferimento e il volume
sico desde fbrica: 31.12.aa). El
relativo al giorno di riferimento
da de vencimiento y su volumen
[m3/a] sono visualizzati in modo
[m3/a] se muestran alternamente.
alternato. Li si pu leggere anche
Se pueden emitir tambin a tramediante M-Bus.
vs de M-Bus.
-5- Modalit Volumi di ritorno:
-5- Modo volumen de retorno:
volumi di ritorno ad alta definizioVolumen de retorno de alta resone in m3.
lucin en m3.
Per tornare alla visualizzazione di Para regresar de nuevo a la indibase:
cacin bsica:
dopo la modalit 5 premere nuoDespus de la visualizacin del
vamente il pulsante.
modo 5, accionar de nuevo el
pulsador.
Impulsgeber
Pulse generators
Anlage hinsichtlich der besonderen Bestimmungen des elektrischen Explosionsschutzes berprfen.
Zum Aufstecken der Impulsgeber
vorher die Staubkappen von den
Kontaktsteckern abnehmen.
QA
Mit zwei eingebauten Impulsgebern ist eine Fernanzeige mglich.
Erster Impulsgeber E1, Reedkontakt:
max. Schaltspannung 24 V,
max. Schaltstrom 50 mA,
max. Schaltleistung 0,25 W/VA,
Durchgangswiderstand 100
20 %.
QA, QAe
Mit eingebautem Impulsgeber,
E200, Induktivgeber EN 50227,
ist eine Fernanzeige mglich:
Versorgungsspannung ca. 8 V=,
Innenwiderstand 1 k.
Der Impuls erfolgt durch nderung der Stromaufnahme von
I 1,2 mA zu I 2,1 mA und
der Spannung von U < 5,9 V zu
U > 6,8 V.
QA

a dry cloth.
8.8.8.8.8.8.
1
E1
92644
3
E200
Typ
Type
Type
Type
Tipo
Tipo
Remove the dust caps from the

contact pins to connect the pulse
generators.
QA
Remote indication can be
achieved with two incorporated
pulse generators.
First pulse generator E1, reed contact:
max. switching voltage 24 V,
max. switching current 50 mA,
max. making/breaking capacity
0.25 W/VA,
contact resistance 100 ,
20%.
QA, QAe
Remote indication can be
achieved with the incorporated
pulse generator, E200, inductive
generator EN 50227:
supply voltage approx. 8 V DC,
internal resistance 1 k.
The pulse is created by changing the current consumption from
I 1.2 mA to I 2.1 mA and
the voltage from U < 5.9 V to
U > 6.8 V.
cp-Wert [Impulse/m3]
cp value [pulses/m3]
Valeur cp [impulsions/m3]
cp-waarde [impulsen/m3]
Valore cp [impulsi/m3]
Valor cp [impulsos/m]
E200
QA 10 DN 25 G I
QA 16 DN 25 G I
QA 25 DN 25 G I
QA 40 DN 25 G I
QA 40 DN 40 G I
QA 65 DN 50 Z
QA 100 DN 80 Z
QA 160 DN 80 Z
QA 250 DN 100 Z
QA 400 DN 100 Z
QA 400 DN 150 Z
QA 650 DN 150 Z
QA 1000 DN 150 Z
500
500
500
500
250
250
187,5
187,5
187,5
187,5
187,5
187,5
187,5
Transmetteurs
dimpulsions
Pour le montage des transmetteurs dimpulsions, retirer au
pralable les cache-poussire
des connecteurs de contact.
QA
Avec deux transmetteurs dimpulsions intgrs un affichage
distance est possible.
Premier transmetteur dimpulsions E1, relais contacts sec ;
tension denclenchement maxi. 24 V,
courant denclenchement maxi. 50 mA,
puissance de coupure maxi.
0,25 W/VA,
rsistance intrieure 100 20%.
QA, QAe
Avec un transmetteur dimpulsions intgr, E200, un transmetteur inductif EN 50227, un affichage distance est possible ;
tension dalimentation 8 V= env.,
rsistance intrieure 1 k.
Limpulsion se produit via une
modification de lintensit de
charge de I 1,2 mA I 2,1 mA
et de la tension de U < 5,9 V
U > 6,8 V.
QAe
Impulsgevers
Explosiegevaar!
Elektrische
installatie m.b.t. de bijzondere
bepalingen van de elektrische
bescherming tegen explosie controleren.
te reinigen.
Voor het aanbrengen van de impulsgevers eerst de stofkappen
van de contactstekkers verwijderen.
QA
Met twee ingebouwde impulsgevers is er een weergave op
afstand mogelijk.
Eerste impulsgever E1, reedcontact:
max. schakelspanning 24 V
max. schakelstroom 50 mA
max. schakelvermogen 0,25 W/VA
Doorlaatweerstand 100 20%
QA, QAe
Bij ingebouwde impulsgever
E200 en inductieve impulsgever
EN 50227 is een weergave op
afstand mogelijk:
Voedingsspanning ca. 8 V=.
Inwendige weerstand 1 k.
De impuls ontstaat door verandering van de opgenomen stroom
van I 1,2 mA naar I 2,1 mA
en van de spanning van U < 5,9 V
naar U > 6,8 V.
Trasmettitori di impulsi Transmisores de

Pericolo desplosione! Con- impulsos
trollare se limpianto elettrico risponde alle norme speciali relative
esplosioni.
Per inserire i trasmettitori di impulsi, rimuovere prima i coperchi parapolvere dalle spine di contatto.
QA
Con due trasmettitori di impulsi
integrati supportata la telesegnalazione.
Primo trasmettitore di impulsi E1,
contatto Reed:
tensione di collegamento max.
24 V,
corrente di collegamento max.
50 mA,
potenza di apertura max.
0,25 W/VA,
resistenza di collegamento 100
20%.
QA, QAe
Con un trasmettitore di impulsi
integrato E200, trasmettitore induttivo EN 50227 supportata la
telesegnalazione:
tensione dalimentazione circa
8 V=,
resistenza interna 1 k.
Limpulso nasce dalla variazione della corrente assorbita
da I 1,2 mA a I 2,1 mA e
della tensione da U < 5,9 V a
U > 6,8 V.
Typ
Type
Type
Type
Tipo
Tipo
E1
QAe 10 DN 25 G I
QAe 16 DN 25 G I
QAe 25 DN 25 G I
QAe 40 DN 25 G I
QAe 40 DN 40 G I
QAe 65 DN 50 Z
QAe 100 DN 80 Z
QAe 160 DN 80 Z
QAe 250 DN 100 Z
QAe 400 DN 100 Z
QAe 400 DN 150 Z
QAe 650 DN 150 Z
QAe 1000 DN 150 Z
-8-
Para enchufar los transmisores

de impulsos, debern quitarse
antes las tapas contra polvo de
los conectores de contacto.
QA
Con los transmisores de impulsos integrados es posible una
indicacin a distancia.
Primer transmisor de impulsos
E1, contacto Reed:
Tensin de conmutacin mx. 24 V,
Corriente de conmutacin mx.
50 mA,
Potencia de conmutacin mx.
0,25 W/VA,
Resistencia de paso 100
20 %.
QA, QAe
Con el transmisor de impulsos
integrado, E200, transmisor inductivo EN 50227, es posible una
indicacin a distancia:
Tensin de alimentacin aprox.
8 V cc,
Resistencia interior 1 k.
El impulso se efecta modificando la absorcin de corriente de
I 1,2 mA a I 2,1 mA y de la
tensin de U < 5,9 V a U > 6,8 V.
E200
10
10
10
10
1
1
1
1
1
1
1
1
1

antideflagrante.
500
500
500
500
250
250
187,5
187,5
187,5
187,5
187,5
187,5
187,5
Wechsel des
Zhlwerks
Changing the counter

a dry cloth.
Anlage hinsichtlich der besonderen Bestimmungen des elektrischen Explosionsschutzes berprfen.

Uitwisselen van het

telwerk
Explosiegevaar! Elektrische installatie m.b.t. de bijzondere bepalingen
van de elektrische bescherming tegen explosie controleren.
te reinigen.
Sostituzione del
totalizzatore
Pericolo desplosione! Controllare se limpianto elettrico risponde alle norme speciali relative
esplosioni.
Cambio del contador

antideflagrante.
A modulator washer is also fitted

in step 4 when replacing a mechanical counter QA by an elec Cuando se cambia un totalizador
Nella sostituzione del totalizzatore
tronic counter QAe.
mecnico QA por un totalizador
Bij het uitwisselen van een memeccanico QA con uno elettroni Step 4, fitting the modulator Lors du remplacement dun toelectrnico QAe, en el paso 4 se
chanisch
telwerk
QA
tegen
een
talisateur mcanique QA par un
co QAe, nel punto 4 va inserito
washer, is not necessary when
inserta adems un disco modulaelektronisch
telwerk
QAe
wordt
in
totalisateur lectronique QAe,
anche un disco modulatore.
replacing an electronic counter
dor.
stap 4 bovendien een modulator- Nella sostituzione del totalizzatore
ltape 4, il faut utiliser de surcrot
QAe by a mechanical counter
Cuando se cambia un totalizador
schijf geplaatst.
un
disque
de
modulation.
elettronico
QAe
con
uno
meccaQA.
electrnico QAe por un totaliza Lors du remplacement dun to- Bij het uitwisselen van een eleknico QA, il punto 4, corrispondendor mecnico QA, no se lleva a
tronisch telwerk QAe tegen een
talisateur lectronique QAe par
te allinserimento del disco moducabo el paso 4, la colocacin del
mechanisch telwerk QA vervalt
un totalisateur mcanique QA,
latore, viene meno.
disco modulador.
stap 4, het gebruik van de modultape 4 est supprime, savoir
latorschijf.
lutilisation du disque de modulation.
Beim Austausch eines mechanischen Zhlwerks QA gegen ein

elektronisches Zhlwerk QAe
wird im Schritt 4 zustzlich eine
Modulatorscheibe eingesetzt.
Beim Austausch eines elektronischen Zhlwerks QAe gegen
ein mechanisches Zhlwerk QA
entfllt Schritt 4, der Einsatz der
Modulatorscheibe.
QA, QAe
Remplacement du
totalisateur
Scheibe ohne Kraftaufwand auf die Antriebsschnecke stecken und den Gewindestift anziehen.
Place the washer onto the actuating worm gear without using force and tighten the setscrew.
Placer le disque sur la vis sans fin dentranement sans quaucune force ne sexerce. Serrer la vis sans tte.
Schijf zonder krachtsinspanning op de wormaandrijving steken en de draadstift aantrekken.
Appoggiare il tappo sulla vite di azionamento senza forzare e serrare il grano.
Insertar el disco sobre el husillo de accionamiento, sin ejercer fuerza, y apretar el tornillo prisionero.
-9-
Wartung
Maintenance
Das Quantometer QA, QAe ist

wartungsfrei. Aus messtechnischer Sicht empfehlen wir eine
berprfung beim Hersteller alle
5 bis 8 Jahre.
The quantometer QA, QAe is Le dbitmtre QA, QAe est sans De quantometer QA, QAe is on- Il misuratore di portata QA, QAe El cuantmetro QA, QAe est
maintenance-free. To ensure
entretien. Dun point de vue mderhoudsvrij. Uit meettechnisch
non richiede manutenzione. Dal
exento de mantenimiento. Desde
measuring accuracy, we recomtrologique, nous recommandons
oogpunt adviseren wij een conpunto di vista metrologico si conel punto de vista de medicin tcmend that the appliance be indeffectuer un contrle auprs du
trole bij de fabrikant om de 5 tot 8
siglia un controllo ogni 5/8 anni
nica, recomendamos la revisin
spected on the manufacturers
fabricant tous les 5 8 ans.
jaar.
da effettuarsi presso il produttore.
por el fabricante cada 5 a 8 aos.
premises every 5 to 8 years.
Technische nderungen, die dem

Fortschritt dienen, vorbehalten.
We reserve the right to make techni- Sous rserve de modifications

cal modifications in the interests of techniques visant amliorer nos
produits.
progress.
Bei technischen Fragen wenden Sie

sich bitte an die fr Sie zustndige
Niederlassung/Vertretung. Die Adresse erfahren Sie im Internet oder bei
der Elster GmbH, Mainz-Kastel.
Elster GmbH
Steinern Strae 19-21
D-55252 Mainz-Kastel
Tel. +49 (0) 61 34/6 05-0
Fax +49 (0) 61 34/6 05-3 90
www.elster.com
If you have any technical questions

please contact your local branch
office/agent. The addresses are
available on the Internet or from
Elster GmbH, Mainz-Kastel.
Maintenance
Pour toute assistance technique,

vous pouvez galement contacter
votre agence/reprsentation la plus
proche dont ladresse est disponible
sur Internet ou auprs de la socit
Elster GmbH, Mainz-Kastel.
- 10 -
Onderhoud
Manutenzione
Technische wijzigingen ter verbete- Salvo modifiche tecniche per migliorie.

ring van onze producten voorbehouden.
Voor technische vragen wendt u zich
a.u.b. tot de plaatselijke vestiging/
vertegenwoordiging. Het adres is op
het internet te vinden of u wendt zich
tot Elster GmbH in Mainz-Kastel.
Mantenimiento
Se reserva el derecho a realizar modificaciones tcnicas sin previo aviso.
Per problemi tecnici rivolgersi alla Puede recibir soporte tcnico en

filiale/rappresentanza
competen- la sucursal/representacin que a
te. Lindirizzo disponibile su In- Ud. le corresponda. La direccin la
ternet o pu essere richiesto alla puede obtener en Internet o a travs
de la empresa Elster GmbH, MainzElster GmbH, Mainz-Kastel.
Kastel.
INSTALLATION INSTRUCTIONS
EARL FLOW SWITCH WITH PENDULUM
Model 107 vLT / 107 vLHT with weighted pendulum
107 vLT
107 vLHTT
I m p o r t a n t
N o t e
Before installation and commissioning of the unit the operating instructions must be read extremely carefully to
avoid possible damage which may invalidate the warranty.
The unit must only be used for the operating conditions as detailed within the enclosed specification..
A l l
1
o t h e r
u s a g e
i s
e x c l u d e d .
General
The flow switches 107vLT / 107 vLHT are only to be used to control liquids and gases in pipes DN 25. The
medium should be free of magnetical parts. The unit must only be uses for the operating conditions as detailed
in the specification. In case of differing operating conditions please contact the manufacturer in writing.
2
Operation
Type 107 vLT / 107 vLHT
When the medium enters in the direction of flow indicated by the arrow it moves the target disc and
weight against the force of the weight in the direction of flow. A permanent magnet is situated at the upper end of the lever and serves to operate one contact, which is located adjacent to the system tube. The
set point is not adjustable.
Installation
The pipe must be cleaned before installing the unit to avoid that operation is impaired by impurities
such as welding beads or sealing compounds.
The flow switch is mounted to the connecting flange such that the arrow situated on the unit points in
the direction of flow. The connecting flange must be in a vertical position (max. deviation 2). The
size, the position of the pipe and the direction of flow are to be found in the specification. Required
straight runs of the pipe 10 pipe diameters upstream and 5 pipe diameters downstream
When installing the unit great care must be taken not to damage the pendulum or target disc and/or
weight. The frictionless play of the pendulum has to be tested before installation.
eb Serie 107vLT 08/2005
DOSCH MESSAPPARATE
1
Wiener Str. 10
D-10999 Berlin
Tel. 030/720 153-0
FAX 030/720 153-61
Technical data
The technical date for which the unit is ranged are to be found in the attached specification. Please contact the manufacturer in writing in case of deviations.
5.
The type, protection class and rupturing capacity of switch contact is to be found in the specification.
A cable of about 30 cm is used to connect the unit.
The bushing which is part of the delivery has to be connected according to the connecting terminal.
Contact arrangement for plug type 713
No flow
Drawing
A drawing with the main measurements is attached.
Attention!
If the installation position is not made as specified the unit will not operate properly.
If the straight runs of the pipe are not sufficient malfunction may be the result. .
Operational conditions which are not in accordance with the specification may have a deviation of the
required set point as consequence.
The rupturing capacity of the switch contact must be strictly observed. Otherwise the switch contact will
be destroyed.
Before removing the unit from the pipe empty the pipe and switch off power..
Maintenance
The proper function of the unit has to be tested periodically, at least once a year. It is the responsibility of
the user to choose the testing method and the time intervals.
It is recommended to return the unit to the manufacturer from time to time for
maintenance.!
eb Serie 107vLT 08/2005
DOSCH MESSAPPARATE
2
Wiener Str. 10
D-10999 Berlin
Tel. 030/720 153-0
FAX 030/720 153-61
Armatures and servo units
Operating instructions for steam and hot water boilers

K002
Edition 2
Replacement for 1
Fig. 1
1.
Full-stroke safety valve springloaded
Fig. 2
Full-stroke safety valve

directly weightloaded
Note
The sectional drawings show the internal construction of the two mainly used valve types. Safety valves are important safety
devices and must prevent high excess pressures in the boiler. To ensure that they will operate reliably, they must be carefully
maintained and the operating instructions strictly observed. Only type-tested safety valves must be used. With the full-stroke
safety valve the required valve stroke is already reached at a 5% excess pressure. With such valves the opening takes place
suddenly at the start of blow-off, also closing after pressure has dropped sufficiently.
2.
Assembly instructions
The blow-off pipe run must be laid safely into the open. The pipe cross-section must be chosen so that no back-pressure
occurs at full blow-off . The attachment must be made to ensure that occurring back-pressure forces can be safely absorbed.
Even in the closed condition, no additional forces from the blow-off piping must act on the safety valve. Provide enough
brackets on the blow-off pipe! The blow-off pipe must have a safe outlet and be safeguarded against freezing. The blow-off
pipe must be provided at its lowest point with a drainage unit which cannot be shut off. Blow-off pipes of safety valves which
are connected to water spaces must be provided with an expansion vessel and a water trap.
3.
Setting
The response pressure setting is checked and lead-sealed by the inspector during the safety test. When setting the response
pressure of a spring-loaded safety valve care must be taken that the taper does not turn at the same time. To prevent this, the
spindle must be held tight when adjusting the spring compression screw. On completion of the pressure setting the spring compression screw must be secured.
4.
Checking for easy movement
Safety valves must be checked at appropriate intervals for easy movement. To do this, the load on the taper must be relieved
by raising the lifting lever, so that the valve opens at the existing operating pressure. This lifting must be possible when the
Page 1 of 2

K002
Edition 2
Replacement for 1
operating pressure amounts to no more than 80% of the response pressure.

In the case of new installations a test for free movement should be made every 3 days. After about 6 weeks this period can be
extended to 7 days, provided that no increase of the force needed for lifting has been found.
An increase in the force required for lifting (at the same boiler pressure) may be caused by the seat and the taper being caked
together, or by encrustation in the spindle passage. In this case a water test is recommended, as well as further measures in
consultation with our after-sales service department.
5.
Response pressure test
At appropriate intervals (in consultation with the inspector), safety valves must be tested to ascertain that the response
pressure still remains within the permissible limits. To do this, the largest
amount of steam which can be generated in
continuous operation must be discharged through the safety valves without the maximum permissible operating pressure being
exceeded by more than 10%. After this test the operating pressure must be lowered by at least 20%, to ensure that the valve
will be completely leaktight when closed.
6.
Repair or replacement
If safety valves leak, an attempt can be made to blow off possibly adhering impurities from the sealing surface by raising the
taper. Should this be unsuccessful, the sealing surface must be reground or replaced. Regrinding should for safety reasons
only be carried out by an experienced craftsman (using a suitable device). The setting of replacement safety valves must again
be acceptance tested by the inspector.
Important:
All work on boilers under pressure and temperature is extremely dangerous! Take appropriate safety measures, e.g.
locking stop valves, preventing unauthorized opening, intermediate venting for tightness check etc.
Page 2 of 2

K004
Edition 1
Replacement for 03 83
Pressure gauge
Test stop valve Connection to the trap
1.
Cross-section of the test connection
General
Pressure gauges (1) must be connected to the steam boiler (steam or hot water generators) by means of a water trap (6). The
permissible operating gauge pressure must be marked on the pressure gauge scale (2) by a permanently clearly visible red
line marking.
2.
Test stop valve
Upstream of each boiler pressure gauge, a stop valve (5) with a connector (5.1) must be installed to accommodate a test
pressure gauge. The connection for the test pressure gauge is standardized as a test spigot with a male M 20 x 1.5 thread (DIN
16 271). With the valve closed (handwheel turned shut) all three outlets (pressure gauge top, test spigot front, venting screw
rear) are shut off from the pressure inlet. A pressure gauge which is pressurized in this condition can be.depressurized with
the venting screw (5.2).
3.
Connect test pressure gauge
Screw the test pressure gauge onto the test spigot by means of a special left/right thread socket. (See test pressure gauge
instructions.)
4.
Testing the boiler pressure gauge
The definitive test of the boiler pressure gauge (1) is carried out by comparison with a verification pressure gauge during the
test by the authorized inspector. Otherwise the zero setting check is generally sufficient. In cases of doubt replace the boiler
pressure gauge and send it in for checking.
Page 1 of 2

K004
Edition 1
Replacement for 03 83
5.
Replacing the boiler pressure gauge
Close test stop valve. The boiler pressure gauge is mounted with a special socket (3) with left/right thread. The valve exit has
left-hand thread and the pressure gauge spigot has right-hand thread. (1/2" pipe thread as standard.) To unscrew the pressure
gauge, hold it with a spanner and turn the socket clockwise as seen from above with a second spanner. The new pressure
gauge must also be tightened again with two spanners. (Do not hold the instrument by force on the casing!) The left/right thread
socket makes it possible to turn the pressure gauge to the most visible angle when tightening. Sealing does not take place in
the thread, but by a flat 6 x 8 mm dia. fibre washer (4) situated between the end faces of the two threaded spigots.
6.
Water trap
Boiler pressure gauges can be damaged by the effect of heat and give a faulty reading as a result. To prevent this with steam
and high-temperature water, the feed piping is arranged as a heat barrier in such a way that the pipe in front of the pressure
gauge only contains condensate at room temperature. If frost threatens, this pressure gauge pipe must, among others,
therefore also be drained via the drain plug (7).
7.
Maintenance
At appropriate intervals the pressure gauge piping must be flushed clean. Very dirty pipes can cause wrong pressure readings
and faulty burner control and must therefore be unscrewed and thoroughly cleaned! Pressure gauge pipes should after cleaning
be filled with distilled water.
Page 2 of 2
Stop valves
K007
Version 4 (01/09)
Contents
1
Safety .......................................................................................................................................................................... 2
7.1
Straight-way type ......................................................................................................................................................... 3
7.2
Angular type................................................................................................................................................................. 4
7.3
Both types.................................................................................................................................................................... 6
7.4
Rating plate.................................................................................................................................................................. 6
Assembly.................................................................................................................................................................... 7
9.1
Installing shut-off valves............................................................................................................................................... 7
9.2
Shut-off valve with relief cone ...................................................................................................................................... 7
9.3
Shut-off valve with limit switch ..................................................................................................................................... 8
10
Setting and Adjustment............................................................................................................................................. 8
11
Start-up ....................................................................................................................................................................... 8
12
Operation.................................................................................................................................................................... 9
13
Shutting down............................................................................................................................................................ 9
14
15
15.1
Lubrication ................................................................................................................................................................. 11
15.2
Packing gland ............................................................................................................................................................ 12
15.3
Bellows ...................................................................................................................................................................... 12
15.4
Re-assembly of the upper part................................................................................................................................... 12
16
Page 1 of 13
Stop valves
K007
Version 4 (01/09)
The shut-off valves delivered by Loos International may only be used in Loos boiler systems and Loos system components.
Assembly, commissioning and maintenance should only be carried out by experienced and qualified personnel. Only a
correctly performed assembly, commissioning and maintenance of the valves ensures proper functioning.
Safety
Hand wheel
Figure 1: Straight-way shut-off valve
Angle-type shut-off valve
Shut-off valves are used to close off or reduce the flow of media in boiler systems.
Page 2 of 13
Stop valves
K007
Version 4 (01/09)
The valve is closed by turning the hand wheel in clockwise direction. It is opened by turning the wheel anticlockwise.
Attention! The use of aids to increase the torque of the hand wheel is not permitted!
7.1
Straight-way type
Nominal
pressure
Material
Nominal
diameter
Nominal
pressure
Material
Nominal
diameter
PN 16
EN-JL1040
DN 15 bis 300
PN 25
1.0619+N
DN 200 bis 500
PN 16
EN-JS1049
DN 15 bis 350
PN 40
1.0619+N
PN 25
EN-JS1049
DN 15 bis 150
Figure 2: Dimensions (in mm)
DN 15 bis 500
Long type for PN 25, DN 500 and for PN 40 from DN 300
All flanges according to DIN EN 1092-1 and 1092-2

DN:
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
500
C, PN 16:
126
126
126
126
150
150
175
175
225
300
400
520
520
520
640
---
---
C, PN 25:
126
126
126
126
150
150
175
175
225
300
400
520
520
520
640
640
640
C, PN 40:
126
126
126
126
150
150
175
225
300
300
400
520
520
520
640
640
640
H1 / H4:
205
205
210
210
225
230
245
265
365
395
425
550
720
775
975
1015 1360
Page 3 of 13
Stop valves
K007
Version 4 (01/09)
DN:
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
500
D, PN 16:
95
105
115
140
150
165
185
200
220
250
285
340
405
460
520
---
---
D, PN 25:
95
105
115
140
150
165
185
200
235
270
300
360
425
485
555
620
730
D, PN 40:
95
105
115
140
150
165
185
200
235
270
300
375
450
515
580
660
755
L:
130
150
160
180
200
230
290
310
350
400
480
600
730
850
980
1100 1350
3,6
4,3
5,3
6,6
9,2
11,6
15,8
21,8
33,0
54,0
69,0
140
240
265
360
---
---
---
---
---
---
---
---
---
---
---
---
---
147
238
339
570
650
710
PN 40:
4,5
4,8
6,2
7,3
10,6
12,6
19,1
26,1
35,0
60,3
88,0
178
305
360
410
720
780
Kvs-value *):
4,7
7,4
11,2
18,3
29,3
44,2
73,2
112,2 173
288
410
725
1145 1635 2220 3180 4530
Zeta-value *):
3,5
4,5
4,8
4,8
4,6
4,9
5,1
4,5
4,6
4,6
Weight in kg:
PN 16; PN 25
with ENJS1049:
PN 25 with
1.0619+N:
5,0
5,1
4,5
4,6
4,7
3,9
4,6
*) Flow coefficient with100% opening degree in m/h **) Flow resistance coefficient
7.2
Angular type
Nominal
Material
pressure
Nominal
diameter
PN 16
EN-JL1040
DN 15 to 150
PN 16
EN-JS1049
DN 15 to 150
PN 25
EN-JS1049
DN 15 to 150
PN 40
1.0619+N
DN 15 to 150
Page 4 of 13
Stop valves
K007
Version 4 (01/09)
Figure 3: Dimensions (in mm)
All flanges according to DIN EN 1092-1 and 1092-2

DN:
15
20
25
32
40
50
65
80
100
125
150
C, PN 16:
126
126
126
126
150
150
175
175
225
300
400
C, PN 25:
126
126
126
126
150
150
175
225
300
300
400
C, PN 40:
126
126
126
126
150
150
175
225
300
300
400
H3:
190
190
195
195
210
210
220
235
325
345
370
D, PN 16:
95
105
115
140
150
165
185
200
220
250
285
D, PN 25:
95
105
115
140
150
165
185
200
235
270
300
D, PN 40:
95
105
115
140
150
165
185
200
235
270
300
l:
90
95
100
105
115
125
145
155
175
200
225
PN 16:
3,7
4,4
5,1
6,5
8,3
11,2
14,6
19,4
29,4
44,0
58,0
PN 25:
4,6
6,4
6,7
7,5
10,1
12,7
17,5
22,0
34,0
49,0
60,0
PN 40:
4,6
6,4
6,7
7,5
10,1
12,7
17,5
22,0
34,0
49,0
60,0
Kvs-value *):
5,2
9,2
15
24
37
58
96
150
235
360
510
Weight in kg:
Page 5 of 13
Stop valves
K007
Version 4 (01/09)
DN:
15
20
25
32
40
50
65
80
100
125
150
Zeta-value *):
2,8
2,9
2,8
2,7
2,9
2,8
2,9
2,8
2,7
2,9
3,0
*) Flow coefficient with100% opening degree in m/h **) Flow resistance coefficient
7.3
Both types
Correlation of temperature - maximum admissible working gauge pressure (intermediate values through linear
interpolation):
Material
Nominal
120 C
150 C
200 C
250 C
300 C
350 C
400 C
450 C
pressure
EN-JL1040
PN 16
16 bar
14,4 bar
12,8 bar
11,2 bar
9,6 bar
---
---
---
EN-JS1049
PN 16
16 bar
15,5 bar
14,7 bar
13,9 bar
12,8 bar
11,2 bar
---
---
PN 25
25 bar
24,3 bar
23 bar
21,8 bar
20 bar
17,5 bar
---
---
1.0619+N
7.4
50 C
100 C
PN 25
25 bar
23,3 bar
21,7 bar
19,4 bar
17,8 bar
16,1 bar
15 bar
14,4 bar
13,9 bar
PN 40
40 bar
37,3 bar
34,7 bar
30,2 bar
28,4 bar
25,8 bar
24 bar
23,1 bar
22,2 bar
Rating plate
All shut-off valve bodies are equipped with rating plates with the following details:
valve type
nominal diameter
nominal pressure
material
manufacturer
CE-sign with named location
year of manufacture
The shut-off valves leave the factory with adequate packing and protection.
Please observe the following instructions:
Protect the shut-off valves against external forces like impact, shock or vibration.
Do not expose the shut-off valves to temperatures below 20C or above +65C.
The coat of varnish protects the shut-off valves from corrosion during transport and storage. Do not damage this
protective paint.
Use suitable transport and hoisting equipment and do not attach this to the hand wheel; for weight see technical data.
Store the shut-off valves in their original packaging.
If packaging damage is noticed on delivery, the carrier should be informed of this damage. When handing over the
goods, the freight carrier has to confirm in writing on the receipt that the packaging is damaged.
If you notice any damage after unpacking the shipment please contact Loos International immediately.
Page 6 of 13
Stop valves
K007
Version 4 (01/09)
Assembly
Assembly and later disassembly should exclusively be carried out by specially trained experienced and qualified
personnel with adequate technical knowledge being authorised for this task by the manufacturer of the system.
Attention! Before starting the assembly, check by the details on the rating plate (nominal diameter, nominal
pressure, material) whether the shut-off valve is suitable for the intended use (medium, pressure, temperature
etc.). Local regulations must be adhered to!
9.1
Installing shut-off valves
Use suitable transport and hoisting equipment and do not attach this to the hand wheel; for weight see technical data.
Protect the shut-off valve against soiling during construction work.
The interior of the shut-off valve and the pipe must be free of foreign particles.
Remove any flange coverings.
Connecting flanges must match.
Centre the seals between the flanges.
Pay attention to the direction of flow when fitting, see label on the shut-off valve.
The spindle should preferably be upright, other fitting positions are possible.
Spindle thread and spindle shaft must remain paint-free.
Piping should be laid and fixed in such a way that harmful shearing, bending and torsion forces are kept away from the
shut-off valve (supports, spring suspension etc.).
To prevent water impact, drain the valves if necessary.
For further information see Technical Information TI024.
9.2
Shut-off valve with relief cone
If the following pressure differences p are exceeded, shut-off valves with relief cones should be fitted:
DN:
125
150
200
250
300
350
400
500
p in bar:
25
21
14
4,5
3,5
1,5
Flow direction
Figure 4: Shut-off valve with relief cone
Page 7 of 13
Stop valves
K007
Version 4 (01/09)
There is a relief cone (3.1) on the cone (3). When the valve is closed, turning the hand wheel in anticlockwise direction first
causes the relief cone lift to be raised. In this way pressure compensation can take place. If the pressure difference p is
undershot, the valve can be opened by turning the hand wheel further with normal strength.
Attention! Pay attention to the marked direction of flow during assembly!
Shut-off valves with relief cone must be installed in such a way that the pressure of the medium rests on the cone (3).
The valve spindle must be in a vertically upright position.
The function of the relief cone is only fully effective in a closed section of pipe. Pressure compensation under the cone
cannot build up if there is a free outward discharge.
If no adequate pressure compensation can be built up with the relief cone, or if the pressure compensation takes too
long, different constructive measures are necessary (e.g. a bypass line).
9.3
Shut-off valve with limit switch
Drawn offset
Figure 5: Shut-off valve with limit switch

Limit switches must be connected according to their function in accordance with the layout plan (see Operating Instructions
K555).
The electrical installation may only carried out by specially trained, experienced and qualified electricians with
adequate technical knowledge.

Shut-off valves are usually either fully open or fully closed. If they are used as throttle valves, suitable intermediate positions
should be selected. The usual position for the intended usage of a valve is set at the first commissioning.
Further setting and adjustment work is not required.
11 Start-up

The start-up of components supplied by Loos International may only be carried out by staff of Loos International
or by people who have been expressly authorised to carry out this work by Loos International.
Assembly and electrical installation should have been completed properly prior to commissioning.
Page 8 of 13
Stop valves
K007
Version 4 (01/09)
Caution! When in operation with high medium temperatures (> 50C) there is risk of injury on touching the shutoff valve. Wear protective gloves!
12 Operation
Shut-off valves are usually either fully open or fully closed. If they are used as throttle valves, suitable intermediate positions
should be selected. The usual position for the intended usage of a valve is set at the first commissioning.
Caution! When in operation with high medium temperatures (> 50C) there is risk of injury on touching the shutoff valve. Wear protective gloves!
The valve is closed by turning the hand wheel in clockwise direction. It is opened by turning the wheel anticlockwise.
Attention! The use of aids to increase the torque of the hand wheel is not permitted!
13 Shutting down
Disassembly of the shut-off valve should exclusively be carried out by specially trained experienced and qualified
personnel having adequate technical knowledge being authorised for this task by the manufacturer of the
system.
Warning! Risk of accidents due to leaking hot medium!
Disassembly may only be carried out when the pipe system is depressurized, cooled and empty.

repair:
Observation/fault:
No flow
Cause
Repair
Valve closed
Open valve
Flange coverings have not been removed
Remove flange coverings
By whom?
Page 9 of 13
Stop valves
K007
Version 4 (01/09)
Observation/fault:
Low flow
Cause
Repair
Valve not sufficiently open
Open valve
Soiled dirt trap
Clean/replace sieve
Blockage in the pipe system
Check pipe system
Observation/fault:
Operation difficult / valve cannot be opened
Cause
Repair
Wrong direction of rotation
Turn anticlockwise to open
Greasing nipple/ fixing device tightened
Release greasing nipple/ fixing device
Dry spindle
Grease spindle
Observation/fault:
By whom?
By whom?
Shut-off valve leaking at the spindle
Cause
Repair
Packing gland not properly sealed
Tighten packing gland screwing
By whom?
Re-pack packing gland
Replace upper part of valve
Bellows damaged
Replace upper part of bellows
Page 10 of 13
Stop valves
K007
Version 4 (01/09)
Observation/fault:
Shut-off valve leaking in seating
Cause
Repair
Valve not firmly closed
Turn the hand wheel without any aids
Soiled medium (solid matters)
Clean the valve, fit dirt traps in front of the valve
Seating/cone damaged through foreign particles
Touch up sealing surfaces (ask about costs!)
By whom?
Replace valve
Differential pressure too high
Fit valve with relief cone

Maintenance of the shut-off valves should exclusively be carried out by specially trained expert personnel having
adequate technical knowledge being authorised for this task by the manufacturer of the system.
Warning! Risk of burns! Maintenance of the valve may only be carried out when the system is depressurized
and has cooled down.
15.1 Lubrication
Greasing nipple/
fixing device
Figure 6: Greasing nipple/ fixing device

The hand wheel can be locked by turning the greasing nipple in clockwise direction.
The thread of the spindle must always be lubricated.
Lubrication can be carried out when the hand wheel is locked or unlocked.
Lubricant: e.g. Klberpaste HEL 46-450
Attention! Ensure that the lubricant is compatible with the medium!
Page 11 of 13
Stop valves
K007
Version 4 (01/09)
15.2 Packing gland
Figure 7: Upper part of the shut-off valve
Figure 8: Packing ring
If the shut-off valve leaks at the spindle (4.2), or better even if the hand wheel can be turned more easily than normal, the
packing gland screw (12) should be tightened until the hand wheel can still just about be turned briskly.
Warning! Risk of accidents due to leaking hot medium! The upper part of the valve must be disassembled for a
re-packing of the packing gland. The upper part of the valve may only be disassembled when the pipe system is
depressurized, cooled and empty.
If the spindle still leaks after moderate tightening, the packing should be removed and replaced with new packing:
Disassemble the upper part of the valve.
Carefully clean off all coating adhering to the packing area and the spindle. Do not use sharp-edged tools! Only fine
sanding paper should be used on the spindle.
Grease the spindle before putting the new packing in place.
Be careful to cut at a slant when cutting a new packing gland seal from the cord (see figure 8).
Place the bias-cut batches opposite to each other (180) respectively.
Press individual packing rings firmly into place.
If leakage at the spindle (4.2) cannot be rectified by tightening the packing gland screw (12) or by re-packing or replacing the
packing gland, then the entire upper part of the shut-off valve should be replaced.
15.3 Bellows
Warning! Risk of accidents due to leaking hot medium! To replace the bellows the upper part of the valve must
be disassembled. The upper part of the valve may only be disassembled when the pipe system is depressurized,
cooled and empty.
15.4 Re-assembly of the upper part
Sealing surfaces must be cleaned and two new seals fitted before assembly.
Put upper part in place.
Screw the hexagon nuts (with grey iron cast valves they are hexagon screws) of the cover screws evenly and
diagonally into place.
The following torques must be observed:
Page 12 of 13
Stop valves
K007
Version 4 (01/09)
DN:
15 - 32
40 - 65
80 - 100
125 - 150
200
250 - 400
500
Nuts / screws
M 10
M 12
M 16
M 16
M 20
M 24
M 27
Torque in Nm
15 - 30
35 - 50
75 - 100
80 - 120
150 - 200
340 - 410
340 - 410
Page 13 of 13
for steam and hot water boilers
Non-return valves
K008
Ausgabe 1
Ersatz fr 11/91
Fig. 1 - Free-low non-return valve
1.
Fig. 2 - Spring-disc non-return valve
General
The cross-sectional drawings show the internal construction of the two most commonly used designs. They do not necessarily
conform exactly to the non-return valves supplied. Non-return valves only allow a medium to flow in the desired direction and
block the return flow. They can therefore be used within a boiler installation for various media, such as steam, hot water, oil,
gas, feed water and similar.
Check valves are not safety units and may leak for various reasons, e.g. through wear, solid particles, external mechanical and
internal chemical stress and deposits.
2.
Installation
Non-return valves with built-in return spring for the valve cone can be installed in any position. Valves without spring must only
be installed in such a position that the cone is pressed onto the sealing surface by gravity. Whether or not a valve has a spring
can be checked by raising the cone with a finger or pencil etc. in the direction of flow to see whether it clearly springs back
when released. Feed water non-return valves are installed in every steam- and hot water boiler plant on the pressure side
between feed pump and boiler. They prevent the return flow from the boiler after each switch-off of the feed pump. Unsuitable
feed water causes the non-return valves to seal unreliably. This is indicated by noises in the feed water tank. This shortcoming
must be corrected as soon as possible by repair or replacement of the non-return valves, since the pump will every time it is
switched on first operate in the steam sector, i.e. virtually dry.
3.
Application limits
Non-return valves are marked with the nominal diameter (DN), the nominal pressure (PN), the material and the manufacturer.
When using valves, this marking must be noted. Please quote the application when ordering spare parts.
4.
Maintenance
Dirt adhering to the valve seat or cone must be carefully removed. Deposits must be removed with solvents if necessary, but
not by scraping off. The valve seat and cone must after such cleaning be ground in again with fine valve grinding paste. The
compression spring installed in most valves only prevents the cone from being held in suspension by the return flow. Complete
leaktightness is only achieved by perfectly ground-in sealing surfaces. It is advisable to keep a spare non-return valve in stock.
Non-return valves should be checked approx. every 6 months for correct functioning. Indirect inspection is recommended, i.e. it is ascertained only by observation to which extent the non-return valve allows medium to flow back. The
isolated spaces must at that time be checked for pressure and/or temperature rise.
Page 1 of 1
Operating instruction for steam and pressurized hot water generators
K014
Edition 1
Replacement for 02/89
1.
Brief description
The thermal expansion of the liquid in the cartridge (see sectional drawing) actuates, via the differential pressure pipe, a
microswitch in the control head, which switches the heating system on or off as the temperature rises!
Safety temperature limiters are fitted with two measuring units (also two cartridges). One measuring unit monitors the other
one. If the limiting unit develops a fault, the monitoring unit switches off.
Cooling fins are only used at high temperatures.
Instruments with remote connection

operate on the same principle. Control head and feeler tube are separate, the differential tube correspondingly long - this then
becomes the remote control line.
2.
Important notes
2.1
Sections A, B and F of the operating instructions must be noted, in as far as controllers and limiters are mentioned in
these sections.
2.2
The purpose of temperature controllers is to control the heating system as a function of the medium temperature, i.e.
the heat requirement. They are of decisive importance for the operation of the heat supply system.
2.3
The purpose of temperature limiters is to switch off and interlock the burner as soon as the permissible medium
temperature is exceeded or not reached. They are of importance for the safety of the superheated water and
superheated steam generation as well as the heat consumption installation.
2.4
Characteristics of the units, particularly their reliability, are emphasized by the TV type test. This is carried out by the
inspection centres of the TV. Type tested appliances carry a rating plate showing the most important data and the
model patent number.
2.5
The replacement of these units or their important components is only permitted to specialist technical personnel who
have appropriate experience and know-how as regards type, setting and electrical connection of these appliances. For
limiters as in 2.3 above, only TV type tested units must be used.
Caution: Before removing the casing top, switch off the power supply (220 V) or take safety measures against electric
shock!
Page 1 of 8
K014
Edition 1
2.6
An appliance unit consists of the controller or the limiter and the corresponding sensor tube. When replacing an
appliance, the sensor tube must also be replaced if the appliance type is not the same. Under no circumstances must
the appliance be fitted into a sensor tube which is too big, already present or already fitted!
2.7
The set points of safety temperature limiters must as a rule not be reset - in special cases only by the expert authorized
for this. (Warning: 220 V current!)
2.8
If despite faults on controllers or limiters, continued operation of the plant is necessary, the boiler must be supervised
particularly carefully and continuously, until the faults have been corrected by an expert.
Bypassing electrical control functions of limiters is not permissible!
2.9
These appliances do not require any special maintenance. The installation site must however be free from vibrations
and the effects of heat, high temperature, frost and moisture.
3.
Technical data
3.1
The maximum permissible control currents depend on the selected control differential as well as the installed power
supply:
Table:
Differential gap
K
3% /
5% /
1,5 % /
*
6%
9%
2%
Max. breaking current

cos = 1 cos = 0,6
10
10
6
250
250
250
Used as
*
TR, TW
STB
TC - temperature controller
TM - temperature monitor
STL - safety temperature limiter
3.2
Operating point accuracy

a)
in the upper third of the scale
b)
at the scale start
TR
TW/STB
1,5 %
4,0 %
+0%
+0%
3.3
2
2
1,2
Max supply volltage

Volt
-5
%
-&
%
Maximum permissible ambient temperature (based on the scale range)

When there is a deviation in the ambient temperature at the control head casing from the calibrated ambient
temperature of +22 oC, a switching point displacement takes place.
Higher ambient temperature = lower switching point
Lower ambient temperature = higher switching point
Page 2 of 8
K014
Edition 1
Scale end value

200 C
TR, TW, TB
250 C
STB
TR, TW
300 C
STB
350 C
TR, TW
STB
0,01 % / K
0,026 % / K
0,014 % / K.m
0,017 % / K.m
on the control head

0,08 % / K
0178 % / K
0,06 % / K
0,13 % / K
on the remote cable

0,047 % / K.m
3.4
0,054 % / K.m
0,09 % / K.m
0,11 % / K.m
Minimum permissible ambient temperature at the capillary line and on the casing during standby of the thermostats.
+ 10oC for control ranges with max. scale value
+300 C
> +200oC
- 35 C for control ranges with max. scale value

>+300oC
o
- 40 C for control areas with max. scale value
+ 200
With sensor temperatures below -10 oC the electric circuit is opened with the STL and the STM (STL). This circuit is with
the STM (STL) automatically closed again.
The STL must be released manually.
3.5
Permissible operating conditions at the sensor

Values only apply to the max. load bearing capacity of the protective tube. The max. seal pressure depends on the
installation conditions and may be correspondingly lower.
General Note:
Due to the general response sensitivity the appliances must only be used with the protective sleeves supplied with
them.
Multiple occupation of protective sleeves is only permissible with 2 or 3 round sensors of 6 mm dia. and protective
sleeves of 15 x 0.75 mm.
When used with 2 sensors, the spacer spring supplied must be fitted in the protective sleeve.
4.
Fitting
4.1
General notes
Installation position of sensor and thermostat are optional, but not so that water can enter the sensor head! Ensure
easy access to the sensor head for operating point setting!
Permissible bend radius of the remote line 5 mm min.
4.2
Opening the casing: Before any opening of the appliance switch off the power supply - danger of electric shock!
Slacken two cheese-head screws on the casing top, remove casing top (fig. 1), feed cable through self-sealing grommet
Pg 11 (fig. 2) and wire as shown in the connection diagram. The connection diagram is situated in the cover.
Page 3 of 8
K014
Edition 1
Closing the case:

Thermostats ATHs 2, 20, 22, 220, 270, 2020 and 2070
Check plastic seal in the bottom section of the casing for correct seating. Position casing top and tighten the two
cheese-head screws (fig. 1).
Page 4 of 8
K014
Edition 1
Examples of connection
5.
Setpoint adjustment
5.1
TS, TL, STL, STM (STL) - (ref. symbols 2, 20, 7, 70)
Remove casing top and reset setpoint adjuster with screwdriver (figs. 3 and 4). Position casing top and screw tight.
Page 5 of 8
K014
Edition 1
5.2
Limiting the setpoint range
The max. selectable setpoint can on the TR be changed downwards by means of an adjustable stop. After switching off the
power supply, back off cheese-head screws (fig. 5). Turn adjustable stop until setpoint marking points to required max.
setpoint (fig. 6).
Tighten cheese-head screws.
6.
Unlocking the STL
Page 6 of 8
K014
Edition 1
After the lower selected limit value (danger temperature) has been passed by about 10% of the scale range, the electrical
control element can be released. Remove cap nut (fig. 7). Press restart knob downwards until the microswitch has been
released (fig. 8). Screw on cap nut (fig. 9).
On Loos switchgear the interlock is as a rule electrical. This dispenses with mechanical interlocking and allows unlocking at
the switch cabinet to take place via the central release switch. The interlock is indicated at the fault signalling unit by switchover of the corresponding fault lamps from GREEN to RED.
7.
Effect of temperature controller and limiter setting on boiler operation and service life
The setting of temperature controllers and safety temperature limiters, particularly in hot water boiler installations, is of
particular importance.
Only a sufficiently wide gap in the setting of the temperature controller from the temperature limiter ensures trouble-free
operation even in low-load periods. Through post-heating after burner switch-off, fault cut-outs of the complete plant may occur
if the switch-off point of the limiter setting is set too close. For this reason it is recommended to maintain at least a 5% distance
of the switch-off point of the safety temperature limiter from the switch-off point of the burner controller or burner monitor.
The switching accuracy and unambiguity depends on the water flow rate at the installation site. For this reason, a sufficient
water flow rate through the boiler or the installation branch must be guaranteed. Too low a water flow rate causes the creation
of laminar flow in the installation pipe and uncontrollable switching operations.
Insufficient differentials between burner starting and stopping points cause high alternating stresses on the boiler and lead to
premature damage on boiler walls. For this reason a -t of at least 6 K should be maintained between burner switch-off and
burner restart.
To prevent frequent starting in extreme low-load operation we install a timer element as standard, which is set to the longest
possible time. The timer element prevents an immediate acceleration of the burner after re-ignition and reduces wear on the
boiler and furnace components. Too short a setting of the timed suppression of the burner control leads to excessive fuel
consumption, increased wear on burner and control units as well as to alternating load damage on the boiler (see also
Operating Instruction - Part H012)
8.
Performance test
A performance test of the temperature controller should be carried out if possible every 3 days by observing the starting and
stopping temperature. Deviations from the preset operating points may have to be corrected. A function test of the safety
temperature limiter must be arranged depending on the type of installation and in consultation with the boiler inspector.
9.
Faults
Provided that the installation of protective sleeve and sensor unit was correctly carried out and checked, the following faults
may occur:
Fault
Pressure drop in the measuring system and therefore delayed control at higher temperature level causes boiler faults through
the response of the safety temperature limiter.
Correction
Replace the temperature controller
Fault
Oxidation of the switching contacts through excessively humid surroundings etc.
Correction
Replace unit. Protect installation site against moisture.
Fault
Uncontrolled switching:
Insufficient water flow rates
Correction
Increase the minimum water flow rate
Check the water feed conditions
Page 7 of 8
K014
Edition 1
With safety temperature limiters the electric circuit is when a measuring system breakage (leak) occurs permanently opened
and the microswitch interlocked. Restarting is impossible; the unit must be replaced before continuing to operate the plant.
Temperature controllers and limiters must only be replaced by qualified personnel. After replacement, all control points must
be checked again including in the case of the safety temperature limiter a check of the switch-off point by the inspector of a
technical inspection organization (TV).
Page 8 of 8
Operating instructions for steam and high-temperature water boilers
Flange gaskets
K021
Edition 3 (05/02)
Replacement for 2 (03/99)
1.
Gasket types
As a replacement for the former asbestos-containing gaskets are used gaskets which are built up as follows:
Multiple layers of thin graphite sheets are bonded together.
with sheet metal reinforcing layers are inserted to prevent possible damage through handling. The total thickness is in principle
2 mm.
2.
Ranges of application
The gasket is used for:

6
6
6
saturated steam and superheated water

superheated steam at all pressure stages
gas.
The gasket is particularly ageing resistant, does not become brittle and has good resistance to temperature fluctuations.
Identification:
The surface is marked by an imprinted network of small lozenges.
3.
Handling/installation instructions
The gaskets must be dry and undamaged.

Import:
The graphite gaskets are sensitive to folding. Care must therefore be taken during installation that no
damage in the form of sharp folds, broken-out areas or similar are present on the graphite layer.
The sealing surfaces must be clean, dry, undamaged and plane-parallel. No pastes or other aids should be used. The gaskets
must be installed without mechanical stress (if necessary use flange joint expander or similar tool as an assembly aid).
It is assumed that bolts of minimum strength class 5.6 are used. These must be tightened cross-wise several times, namely:
6
6
6
6
during the 1st pass with approx. 35% of the max. torque
during the 2nd pass with approx. 70%
only during the 3rd pass must the max. torque be applied.
Since the increase in tightening torque causes the earlier bolts to yield, it is necessary to check, by a 4th pass after
reaching the max. torque, that all bolts are uniformly prestressed. Only now can any other tightening sequence be used.
Important:
To achieve the max. prestress, the threads and both contact surfaces (nut and head) must be free from
rust and generously coated with an MoS2-containing bolt lubricant.
Page 1 of 2
Operating Instruction for steam- and hot water boilers
Flange gaskets
K021
Edition 3 (05/02)
Replacement for 2 (03/99)
4.
Torque
screw thread
bolting torque (Nm)
M8
12
M 10
24
M 12
40
M 14
65
M 16
100
M 18
140
M 20
200
M 22
280
M 24
350
M 27
500
M 30
700
Bolting torque refere to property class 5.6.
5.
Requirements before and

during commissioning
As a rule, several weeks pass from the installation to the commissioning of the gaskets. Since during this time some of the
prestress may be lost through bedding down and expansion, the tightness of the bolts must be checked again before
commissioning.
6.
Ordering spare parts
Replacement gaskets should in principle only be obtained from us, since only in this way can you be sure to receive the correct
gaskets and to avoid consequential costs through premature gasket failures.
To ensure quick and reliable replacements, please note the instructions on the cover of your operating manual folder.
7.
Safety informations
There is an enormous risk for accidants when working on boilers under pressure and temperature. Take safety measures such
as blocking off, intermediate aeration for leak detection test, etc.
Page 2 of 2
Inspection openings
steam and water side
for Steam and hot water generators and containers
K022
Version 16 (07/08)
Contents
1
Safety .......................................................................................................................................................................... 2
Assembly .................................................................................................................................................................... 5
9.1
Special safety instructions for assembly....................................................................................................................... 5
9.2
Fitting the Seals ........................................................................................................................................................... 5
9.3
Fitting the insulation cover............................................................................................................................................ 8
10
Start-up ....................................................................................................................................................................... 8
11
12
Care and Maintenance ............................................................................................................................................. 10
13
Replacement Parts ................................................................................................................................................... 10
Page 1 of 12
Inspection openings
K022
Version 16 (07/08)
B006/B009/B011 Recurring inspections for shell boilers (external and internal inspections and water pressure tests)
These Operating Instructions apply for steam and hot water generators and for containers that have been supplied by Loos
International and which are fitted ex works with inspection openings.
Seals or replacement parts for steam or water side inspection openings that are supplied by Loos International may only be
installed in the corresponding openings of Loos products, since they have been calculated and designed to fit these
products. Any other use is not use in accordance with the regulations and is therefore not permitted.
Safety
Seals that have been removed must be disposed of according to the regionally valid environmental protection regulations so
that they cause no danger to people or the environment.
Danger! Leaking or faulty seals may lead to a leakage of the medium and thus to serious scalding, which may
even be fatal. In such a case, the boiler system is to be switched off and secured immediately. Only when the
system has cooled down and emptied and the seals have been replaced may the system be started up again.
These Operating Instructions contain information about the safe operation of inspection openings on steam and hot water
boilers and containers. These inspection or cleaning openings allow internal inspections or cleaning work to be carried out.
Inspection openings consist of the closure ring (either a raised-edge ring or a conical ring) (1) welded into the pressure
vessel, the cover (2) with screw bolt (3) and nuts (4), one or two brackets (5) and the seal (6). In addition, a washer (7) is
installed per screw bolt.
Page 2 of 12
Inspection openings
K022
Version 16 (07/08)
Man hole
Head hole
Part
Designation
Closure ring
Cover
Screw bolt
Nut
Bracket
Seal
Washer
Hand hole
Figure 1: Types of inspection opening
The internal pressure presses the cover (2) onto the seal (6). Using the correct seal is essential to achieve reliable sealing.
Inspection openings may be covered with thermal insulation in order to prevent unnecessary heat losses.
Typical dimensions for closure rings are, for example:
Oval opening dimensions of 300 mm x 400 mm or 320 mm x 420 mm (also called a man hole).
Oval opening dimensions of 220 x 320 mm (also called a head hole).
Oval opening dimensions of 80 x 120, 100 x 150 mm or 115 x 165 mm (also called a hand hole).
Seals should be designed to meet the corresponding pressure and temperature requirements. In addition, they must be
suitable for the medium used. Basically, the regional and national regulations for pressure vessels should be followed. For
high-pressure boilers, only suitable, tested seals may be used. Different seals are therefore used in accordance with the
following table:
Page 3 of 12
Inspection openings
K022
Version 16 (07/08)
Seal
Description
Area of use in terms of
Approval or comment
Press and
Pressure vessel
temperature
Rubber seal
MH 40
seal
Black rubber seal with a

white marking on the edge
max 1 bar
Low-pressure steam boiler
max. 120 C
Container
white, rectangular, 5.5 mm

thick, cord-shaped PTFE
seal, endless strip from
roller
max. 40 bar
High-pressure steam boiler
max. 250 C
High-pressure hot water

boiler
High-pressure Container
Approval for high-pressure

boiler to 40 bar
Approval number
TV.D. 04-012.d
Only for spare part supply

NOVASEALseal
NOVAPHITseal
silvery-light, sharp-edged,
rectangular, 8 or 10 mm
thick, plane-parallel fabric
rubber seal without rubber
coating
max. 40 bar- High-pressure steam boiler
4 or 6 mm thick planeparallel graphite seal with

stretch metal inlay
max. 40 bar
max. 250 C

boiler
max. 250 C
Container

boiler to 40 bar
Approval number
TV.D.05-013.D
Container

boiler to 40 bar
Approval number
TV.D.05-004.D

PSM 300/C-2seal
3 mm thick plane-parallel
graphite seal with spike
sheet metal inlay
max. 40 bar
Heating boiler
max. 250 C

boiler

boiler to 40 bar
Approval number
TV.D.06.010d
Container
Original equipment
thoenes SL /
SP seal
3 mm thick plane-parallel
graphite sear with
stainless steel inlay
max. 40 bar
Heating boiler
max. 250 C

boiler

boiler to 40bar
Approval number
TV.D.08.017d
Container
Original equipment
Page 4 of 12
Inspection openings
K022
Version 16 (07/08)
Seals and inspection openings on the steam and water side are sufficiently protected ex factory and packed suitably for
transporting.
Please note the following:
Never expose the seals to temperatures which are below -20C or above +50C
Always protect the seals against wetness and the effects of moisture.
Store all seals away from direct light and lying completely flat in the original packaging. Because seals are subject to a
natural ageing process, it is essential that you note the use-by date (if provided).
If on receipt of the delivery (see also chapter on "Assembly") it is found that the packaging is damaged, the dispatch
driver must be informed of such damage. When the goods are handed over by the driver, he must confirm that the
packaging is damaged on the receipt slip.
Assembly
For safety reasons, these seals should only be replaced by Loos International or specialist personnel authorised
by Loos.
Important: Seals must be replaced each time an inspection opening is opened. It is generally not
possible to reuse seals.
9.1
Special safety instructions for assembly

Danger! Leakage of hot medium can cause serious scalding. Danger of water damage. An over-wide gap
between the cover neck and the closure ring can cause the seal to slip out under operating pressure. The leaking
medium can cause severe scalding.
Leaks during heating up that cannot be rectified by tightening indicate that the cover and seal are not fitted
properly. For safety reasons, it is strictly forbidden for people to bend over the opening or standing in front of the
opening when tightening the equipment. When carrying out this work, assembly personnel must stay as far away
as possible to the side of the opening in question. Make sure that sufficient escape routes are always kept clear.
Excessively violent tightening may cause the seal to slip out. If the seal slips out, the part of the system in
question must be depressurised immediately. The closures and seals in question should be checked for damage
and distortion and resealed. Damaged seals may not be re-used under any circumstances.
Seals in which leaks are found during operation must be replaced at once. If this does not happen, the seal may
fail suddenly and unexpectedly. This can cause serious injury to people and damage to equipment.
9.2
Fitting the Seals
Before fitting the seals, please note the following instructions:
Before opening an inspection opening, always make sure that there is no water in the container and that the container is
completely unpressurised.
Page 5 of 12
Inspection openings
K022
Version 16 (07/08)
Clean the sealing surfaces on the cover (2) and closure ring (1) after removing the cover carefully with a scraper. When
cleaning, take care to ensure that the sealing surfaces are not damaged. When scraping and shaving, always work
carefully in a circular direction.
Before installing the new seal, remove any residues from the sealing surfaces of the cover and closure ring so that the
metal is shining.
Replace closure systems (cover and closure ring) with damaged sealing surfaces immediately.
Warning! Danger of serious injury or material damage from leakage of the medium. Sealing pastes and
separators may not be used under any circumstances when installing the seals. This products could cause the
seal to slip off the sealing surface under pressure.
Before installing each seal, the following points should be precisely checked individually for safety reasons:
Does the quality of the seal meet the requirements (see "Technical Data")?
Do the dimensions of the seal precisely match the cover?
If the seal completely free from external damage, scratches or dents?
Has the use-by date (if there is one) not yet been reached?
If the surface even and free from cuts, edges and notches?
When installing covers and seals, please note the following:
All inspection openings are carefully and precisely mounted in the factor.
Important: When covers are installed at the factory, care is taken to ensure that the installation position is
correct by checking that the stamps with the year and serial number (e.g. 05/111) on the cover and ring are on
the same side (see arrow in the illustrations of hand hole, head hole and manhole). The material designations
are not important for the installation position. With spare parts deliveries, this rule does not apply; nonetheless, it
may be necessary to install the cover turned around by 180 if the this means that the gap between the ring and
the cover is more even and smaller.
16 bar
16 bar
Hand hole + Head hole
Man hole
The precondition is a firm positioning of the sealing surfaces on each other (see 1 in Figure: 2). If the cover is not fully in
position (see 2 in Figure: 2), it will be necessary to work on the outside rim of the cover or the clear ring width (see 3 in
Figure: 2).
Page 6 of 12
Inspection openings
K022
Version 16 (07/08)
Figure 2: Assembly layout
Thinly apply lubricant "HT-Optimol assembly and high-temperature paste, Loos ident. number: 10024910 to the thread,
the thread sections of the nuts and on both sides of the washer.
Degrease and clean the sealing surfaces on the cover and locking ring as described, polish to a metallic shine and dry.
Apply the seal to the sealing surface of the cover.
With MH 40 sealing:
Splice the end over a length of around 20 mm on a clean substrate so that the end of the strip runs out without
smoothly (Figure I).
Remove the cover strips from the adhesive surface
Starting on a longitudinal side (see Figure II), stick the sealing in the middle onto the sealing surface of the
cover. (Figure II)
Close the sealing ring. To do this, stick the sealing over the spliced end (Figure III).
Trim the overlapped end in such a way that around 120% of the material is left at the point of connection
(Figure IV).
5
Figure I
Figure II
120 %
Figure III
Figure IV
Clean the sealing surfaces of the cover and closure ring as described and polish them until shiny.
Position the cover with the seal in the closure ring and roughly align.
Page 7 of 12
Inspection openings
K022
Version 16 (07/08)
Check closure to ensure the gap between the cover (2) and the locking ring (1) is of an even width, check if necessary
and/or twist cover into installation position. The cover (2) and locking ring (1) should not jam, since this would prevent a
proper seal.
Note: On average, in the tensioned state, the gap should be max. 4 mm and should be as small as possible.
2 mm is ideal, but this is not always possible because of the welding distortion and other manufacturing-related
processes.
Note: A torque wrench must be used to tighten the nuts. Although the tightening torque of the screws is greater,
the screws should not be tightened any more strongly, since the brackets on the supports will be crushed.
The inspection opening screws should be tightened as follows:
Opening
diameter
9.3
Thread
Torque
Opening
diameter
Thread
Torque
80 x 120
M 16
100 Nm
220 x 320
M 24
300 Nm
100 x 150
M 16
100 Nm
300 x 400
M 24
300 Nm
115 x 165
M 20
180 Nm
320 x 420
M 24
300 Nm
Fitting the insulation cover
After commissioning has finished, the inspection opening must be closed by the insulation cover.
Note: The insulation cover on the inspection opening prevents the danger of burns from the hot surface and
reduces heat losses from the boiler.
10 Start-up
For safety reasons, the first start-up should be carried out solely by Loos International or by specialist staff
authorised by Loos.
In the high-pressure range, sealing materials are frequently used, for technical reasons, which only achieve their final state
under particular operating conditions (tempeature and pressure). It is therefore absolutely essential, during powering up of
the boiler, when the pressure starts to rise bothin the cold and the warm state to carefully tighten the nuts (4) constantly
(approx. every 10 to 15 minutes) at regular intervals in order to achieve sufficient, even surface pressure. Correct tightening
during the heating up phase, according to the regulations, is vital for permanent leak-tightness.
If it is found during start-up that the torque has remained constant between tightening, the period between tightening
operations can be increased to 20-25 minutes.
During start-up or when the cold water pressure sample is taken, there may be minor leaks around the NOVASEAL seal,
for example. Final, permanent leak-tightness is only achieved after the operating pressure and temperature are reached for
the first time, assuming that the seal has been installed according to the operating instructions and regularly tightened during
start-up, as described above.
For the MH 40: Approx. 15 Min. after the operating state has been reached, the screws should be tightened to the permitted
torque.
Page 8 of 12
Inspection openings
K022
Version 16 (07/08)
The tightening torques must then be monitored every day until it is certain that the torque remains the same and no further
tightening is required.
During start-up, make sure that the boiler content is sufficiently mixed through to give an even temperature distribution.
This is achieved as follows:
Steam boiler: opened start-up valve, or steam removal shutoff valve opened by approx. 1-2 turns.
Hot water boiler: secured water flow during burner operation.

Warning! Medium leakages may cause injury. A new seal should basically be used every time an inspection
opening is opened.
After commissioning has finished, the inspection opening must be closed by the insulation cover.

repair:
Observation/fault:
Seal slips out
Cause
Repair
Gap too wide between cover neck and ring
Renew or replace cover and insert new seal
Excessive tightening required at start-up
Insert new seal
Boiler heats up too quickly
Insert new seal and start up boiler with low load up

to haf operating pressure
Excessive use of sealing pastes or separators
Clean sealing surface and insert new seal
Observation/fault:
By whom
Leaks during heating up or after exchange
Cause
Repair
Nuts not tightened at start-up
Tighten nuts; it may even be necessary to insert a

new seal under some circumstances
Cover and ring not correctly in position (e.g. cover

pressing on ring, can be seen by grooves) or cover
does not fit ring
Replace cover
Sealing surface not in a suitable condition
Clean sealing surface
Excessive use of sealing pastes or separators
Clean sealing surface and seal and insert new seal
By whom?
Page 9 of 12
Inspection openings
K022
Version 16 (07/08)
Cause
Repair
Boiler heats up too quickly
Insert new seal and start up boiler at low load up to

half operating pressure
Observation/fault:
By whom?
Leaks during operation and efflorescence
Cause
Repair
Nuts not tightened on start-up
Insert new seal
By whom?
Incorrect installation
Wrong seal
Temperature layers after long heater operation
Carry out heater operation whilst simultaneously

letting off steam slightly or ensure sufficient water
circulation
Vacuum states after starting up after long down

times with closed shut-off valves
Start up boiler whilst letting off a little steam or with

sufficient water circulation
Observation/fault:
Excessive force required to open nuts on screw bolt
Cause
Repair
Lack of lubricant or unsuitable lubricant
Use suitable lubricant and replace cover if

necessary
Bracket damaged or bent
Replace bracket
Screw bolt damaged or bent
Replace cover
By whom?

Steam and water side inspection openings must be checked for leaks at least every three months, during initial start-up and
if there is any suspicion of a leak. Covered inspection openings must be uncovered first. Otherwise, secure positioning is to
be checked during maintenance and the inspection openings should be monitored for anything that is unusual. Checks must
be carried out at more frequent intervals after a leak.
Note: All bracket closures are provided with special seals. Standard trade seals must not be used as a substitute
under any circumstances. Only Loos International seals may be used.
Page 10 of 12
Inspection openings
K022
Version 16 (07/08)
Note: As a rule, the gap between the cover and the ring also fits with subsequent deliveries. To be safe, it is
recommended that the clear internal dimension is measured at the ring on the sealing side lengthways and in the
circumferential direction of the boiler / container using a calliper gauge. Alternatively, it can also be determined
using a template.
Note: The nuts have a particularly high design to reduce the load on the thread and the screw bolts are made
from stronger material. Spare parts in this area may therefore only be obtained from Loos International.
For existing inspection openings without insulation, the following rectangular insulating covers are available:
Inspection opening
Description
ID number
Manhole 420x320
Manhole cover 650 mm x 650 mm
013269.1
Manhole 400x300
Manhole cover 650 mm x 650 mm
013270.1
Headhole 220x320
Headhole cover 420 mm x 520 mm
013268.1
Handhole 100x150 or 115x165
Handhole cover 320 mm x 320 mm
013267.1
Lubricant ("HT-Optimol assembly and high-temperature paste) for the thread on the screw bolts is available under ID
number 10024910.
Important: For new boilers, the seals PSM 300/C-2 or thoenes SL / SP are normally used. For
replacement seals, the seal MH 40 should preferably be used. NOVASEAL and NOVAPHIT
seals should only be used if there are problems with leak-tightness because of uneven or damaged
sealing areas. These seals are thicker and can therefore compensate for unevenness better .
For safety reasons, these seals should only be replaced by Loos International or specialist personnel authorised
by Loos.
The following is a table of the most common spare part seals which could be used (for areas of use, see
Chapter 7):
Inspection opening
Seal
ID number
All inspection openings
MH 40
012942.1
NOVASEAL
002265.1
NOVAPHIT
012304.1
NOVASEAL
002264.1
NOVAPHIT
012303.1
Manhole 320x420
Manhole 300x400
Page 11 of 12
Inspection openings
K022
Version 16 (07/08)
NOVASEAL
002262.1
NOVAPHIT
012302.1
NOVASEAL
002253.1
NOVAPHIT
012300.1
NOVASEAL
002258.1
NOVAPHIT
012301.1
Head hole 220x320
Hand hole 100x150
Hand hole 115x165
Page 12 of 12
DIN EN ISO 14001
DIN EN ISO 9001:2000
Zertifikat: 01 104 9254
Einbau- und Bedienungsanleitung

fr Gasfilter Serie HF 2000
Achtung! Bitte lesen Sie diese Hinweise vor Installation und Inbetriebnahme.
Das Produkt muss entsprechend gltiger Vorschriften installiert und betrieben werden!
Beschreibung
Gasfilter der Serie HF 2000 werden eingesetzt, um nachfolgende
Armaturen und / oder Regelgerte gegen Verschmutzung zu
schtzen. Fremdpartikel, die grer gleich 50 m sind, werden
filtriert. Gasfilter Serie HF 2000 entsprechen den Anforderungen
folgender Normen und Richtlinien: DIN 3386, Gasgerterichtlinie
90/396/EG, Druckgerterichtlinie 97/23/EG, russischer GOST und
ungarischer MBVTI Anforderungen.
Montage
Montage- und Wartungsarbeiten sind ausschlielich von sachund fachkundigem Personal auszufhren!
Verwenden Sie keine beschdigten, unsachgem reparierten oder
kurzzeitig unzulssig hohen Temperaturen ausgesetzte Gasfilter
(zugelassener Temperaturbereich -20C bis 80C).
Beim Einbau ist die Durchflurichtung (Pfeil auf dem Gehuse)
einzuhalten. Staubschutzstopfen sind zu entfernen!
Vorzugsweise den Filter mit Deckel senkrecht nach unten einbauen,
damit bei Reinigungsarbeiten kein Schmutz im Filtergehuse bleibt.
Nur Rohre mit ordnungsgem konisch geschnittenen und
normgerechten Gewinde verwenden.
Nur zugelassene Gewindedichtmittel verwenden.
Unzulssige mechanische Belastungen vermeiden, um Risse im
Filtergehuse (Undichtheiten) auszuschlieen.
Aufschriften oder Markierungen am Filtergehuse oder Deckel
drfen nicht unkenntlich gemacht werden.
Dichtheitsnachweis
Nach dem Einbau und vor Inbetriebnahme des Filters mu die
Anlagendichtheit unter Druck geprft werden. Dazu mu eine
gengend lange Zeit vergehen, damit der gesamte Innenraum mit Gas
gefllt ist. Um die Gewindeanschlsse, die Abdichtung zwischen
Gehuse und Deckel sowie um eventuell vorhandene Mestutzen ist
mit einem Pinsel konzentrierte Seifenlauge (oder ein anderes
anerkanntes Dichtheitsprfmittel) aufzutragen. Es drfen keine Blasen
(Undichtheiten) sichtbar werden! Nach der Prfung ist die Seifenlauge
sauber abzuwischen.
GF-IO-DE.EN-01.2003
Achtung
Die Filter sind nur mit dem auf dem Typschild angegebenen
maximalen Betriebsdruck zu betreiben! Unzulssig hohe
Betriebsdrcke knnten den Filter beschdigen und zu mglichen Undichtheiten fhren. Undichtheiten sind unbedingt
auszuschlieen! Die Missachtung dieser Anleitung kann zu
Undichtheiten fhren, die Feuer oder Explosionen und somit
Sach- und Personenschden oder den Verlust von Menschenleben verursachen knnen!
Wartungsarbeiten
Wechsel des Filtereinsatzes wie folgt:
Gaszufuhr unterbrechen (Gasleitung gasfreischalten)
Deckelschrauben lsen. Es ist zu beachten, da wechselseitig die
jeweils gegenber liegende Schraube gelst werden. Deckel
abnehmen und sicher ablegen.
Filtereinsatz entfernen.
Neuen, gertespezifischen Fitereinsatz gem Vorschrift einsetzen.
Beachten Sie dabei den Filtermattenaufdruck Austritt!
Eventuell vorhandene Sttzgitter (vor und hinter der Filtermatte)
sind unbedingt wieder einzusetzen.
Der Dichtring im Filterdeckel sollte stets mit einem neuen Dichtring
gleichen Durchmessers ausgewechselt werden.
Es ist zweckmig, die selbstfurchenden Deckelschrauben bei
der Montage durch metrische Innensechskantschrauben zu
ersetzen.
Es sind nur zugelassene Orginal-Ersatzteile zu verwenden! Der
Zusammenbau erfolgt in umgekehrter Reihenfolge, wobei das
wechselseitige Anziehen der jeweils gegenber liegenden Schrauben
einzuhalten ist. Das vom Nenndurchmesser der Schraube abhngige
zulssige Anzugsdrehmoment ist einzuhalten!
Vor der Inbetriebnahme der Anlage mu die Anlagendichtheit
nachgewiesen sein (siehe Abschnitt Dichtheitsnachweis).
Zur Gewhrleistung eines konstanten Gasdurchflusses wird
empfohlen, mindestens einmal jhrlich den Filtereinsatz zu wechseln.
Je nach Verschmutzungsgrad kann auch ein krzeres Intervall
notwendig sein.
Mestutzen (Druckabnahmestellen) drfen nicht entfernt werden.
Betrieb der Anlage
Gasfilter der Serie HF 2000 drfen nur innerhalb der zulssigen
Umgebungstemperatur und nur bis zum maximal zulssigen
Betriebsdruck eingesetzt werden.
Typenbersicht
Betriebsdruckklassen
Typ
Anschlu
A
Gew indeanschluss
GF40M - 44
GF60M - 66
GF60M - 88
GF80M - 1010
GF80M - 1212
GF80M - 1616
Flanschanschluss
GF 25MF - 88
GF 40MF - 1212
GF 50MF - 1616
GF 65MF - 2020
GF 80MF - 2424
GF100MF - 3232
GF125MF - 4040
GF150MF - 4848
Rp
Rp
Rp
Rp
Rp
Rp
1/2
3/4
1
1 1/4
1 1/2
2
DN
DN
DN
DN
DN
DN
DN
DN
25
40
50
65
80
100
125
150
GasfilterErsatz teilset
Pmax in bar
B
C
KIT-GF 40M
KIT-GF 60M
KIT-GF 80M
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
60MF
80MF
80MF
65MF
80MF
100MF
125MF
150MF
Mertik Maxitrol GmbH & Co. KG
Mertik Maxitrol GmbH & Co. KG Branch Office
Warnstedter Str. 3, 06502 Thale, Germany

Tel.: +49-3947-400-0, Fax: +49-3947-400-200
Industriestrasse 1, 48308 Senden, Germany

Tel.: +49-2597-9632-0, Fax: +49-2597-9632-99
www.mertikmaxitrol.com
DIN EN ISO 14001
DIN EN ISO 9001:2000
Instructions for Installation and Operation

HF 2000 Series Gas Filters
Caution: Please read these instructions prior to installation and operation.

This product must be installed and operated according to all applicable regulations!
Description
HF 2000 Series gas filters protect downstream components
against particulate contamination. They filter particulate
contamination exceeding or equal to 50 m. HF 2000 Series
gas filters are approved according to the following
standards or normative documents: Gas Appliance Directive
90/396/EG, Pressure Equipment Directive 97/23/E, Russian
GOST and Hungarian MBVTI requirements.
Installation
Only authorized persons may install, maintain or service
HF2000 gas filters.
Do not use a gas filter that appears to have been damaged
in any way, improperly repaired or subjected to excessively
high temperatures (certified ambient temperature range 20C to 80C / -4F to 176F).
When installing a gas filter, assure that gas flows in the
direction as indicated by the arrow on the casting. Remove
dust caps!
Mount gas filters preferably with the lid facing down, so that
the force of gravity will cause most particles to fall out of the
housing during cleaning procedures.
Use only properly (taper) threaded pipes and approved
sealants.
Avoid excessive mechanical loads which could cause tears
in the body casting and lead to leakage.
Do not tamper with or paint over labels on the housing or
lid.
Leak Testing
Perform a leakage test after installation and maintenance
work. Allow sufficient time for the filter housing to completely
fill with gas. Apply a recognized leak test solution to the thread
connections, the seal between housing and lid and any
pressure tap ports. No bubbles (leaks) should appear! After
testing wipe all surfaces clean.
GF-IO-DE.EN-01.2003
Note
Operate filters only up to the maximum operating pressure
indicated on the label! Excessively high operating pressure
can damage the filter and cause leakage. Absolutely no
leakage should occur! Failure to follow these instructions
could result in a gas leak which could lead to a fire or
explosion, causing property damage, personal injury or loss
of life!
Maintenance
Replacement of filter insert:
Turn off gas supply.
Loosen the filter lid screws alternately on opposite sides.
Remove the lid and put it safely aside.
Remove used filter insert.
Install a new filter insert in the identical position as the
one replaced. One side of the insert is marked outlet to
facilitate proper installation.
Be sure to reinstall wire mesh supports (if present) on either
side of the filter insert.
Always use a new rubber gasket of appropriate diameter
when replacing the filter lid.
During re-assembly, it is advisable to replace the selfthreading lid screws with metric screws of the same size.
Use only genuine spare parts! Re-assemble the filter in
reverse order, alternately tightening opposite screws. Do not
overtorque the screws.
Conduct a leak test (see Leak Testing, above) prior to
operating the system.
To ensure a constant gas flow, filter inserts should be replaced
at least once a year. Depending on degree of dust & debris a
shorter interval may be necessary.
Pressure taps should not be removed.
Operation of appliance
HF 2000 Series gas filters can only be operated within the
certified temperature range and the maximum admissable
operating pressure.
Models
Type
Connection
Operating Pressure
Classes
Pmax in bar
A
Threaded connection
GF40M - 44
Rp
GF60M - 66
Rp
GF60M - 88
Rp
GF80M - 1010 Rp
GF80M - 1212 Rp
GF80M - 1616 Rp
Flanged connection
GF 25MF - 88
DN
GF 40MF - 1212
DN
GF 50MF - 1616
DN
GF 65MF - 2020
DN
GF 80MF - 2424
DN
GF100MF - 3232
DN
GF125MF - 4040
DN
GF150MF - 4848
DN
1/2
3/4
1
1 1/4
1 1/2
2
25
40
50
65
80
100
125
150
Gas Filter
Service Kit
C
KIT-GF 40M
KIT-GF 60M
KIT-GF 80M
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
KIT-GF
60MF
80MF
80MF
65MF
80MF
100MF
125MF
150MF
Mertik Maxitrol GmbH & Co. KG
Mertik Maxitrol GmbH & Co. KG Branch Office
Warnstedter Str. 3, 06502 Thale, Germany

Tel.: +49-3947-400-0, Fax: +49-3947-400-200
Industriestrasse 1, 48308 Senden, Germany

Tel.: +49-2597-9632-0, Fax: +49-2597-9632-99
www.mertikmaxitrol.com
Electric multi-turn actuators

SA 07.1 SA 48.1
SAR 07.1 SAR 30.1
AUMA NORM
Certificate Registration No.

12 100/104 4269
Operation instructions
Multi-turn actuators SA 07.1 SA 48.1 / SAR 07.1 SAR 30.1

AUMA NORM
Scope of these instructions:
These instructions are valid for multi-turn actuators of the type range
SA 07.1 SA 48.1 and SAR 07.1 SAR 30.1 in version AUMA NORM.
These operation instructions are only valid for clockwise closing, i.e.
driven shaft turns clockwise to close the valve.
Table of contents
Page
1. Safety instructions
1.1
Range of application
1.2
Commissioning (electrical connection)
1.3
Maintenance
1.4
Warnings and notes
4
4
4
4
4
2.
Short description
3.
Technical data
4. Transport, storage and packaging

4.1
Transport
4.2
Storage
4.3
Packaging
7
7
7
7
5.
Mounting to valve/ gearbox
6.
Manual operation
10
7. Electrical connection
7.1
Connection with AUMA plug/ socket connector
7.2
Motor connection for the sizes SA(R) 25.1/SAR 30.1 SA 48.1.
7.3
Motor connection for special motors
7.4
Delay time
7.5
Controls made by AUMA
7.6
Heater
7.7
Motor protection
7.8
Remote position transmitter
7.9
Limit and torque switches
7.10
Fitting of the cover
11
11
12
12
12
12
12
12
12
13
13
8. Opening the switch compartment

8.1
Removing the switch compartment cover
8.2
Pulling off the indicator disc (option)
14
14
14
9. Setting the limit switching

9.1
Setting the end position CLOSED (black section)
9.2
Setting the end position OPEN (white section)
9.3
Checking the limit switches
15
15
15
15
10. Setting the DUO limit switching (option)

10.1
Setting the direction CLOSE (black section)
10.2
Setting the direction OPEN (white section)
10.3
Checking the DUO switches
16
16
16
16
11. Setting the torque switching

11.1
Setting
11.2
Checking the torque switches
17
17
17
12. Test run

12.1
Check direction of rotation
12.2
Check limit switching
18
18
18
13.
19
Setting the potentiometer (option)
14. Setting the electronic position transmitter RWG (option)

14.1
Setting for 2-wire system 4 - 20 mA and 3-/ 4-wire system 0 20 mA
14.2
Setting the 3-/ 4- wire system 4 20 mA
20
21
22

AUMA NORM
Page
15.
Setting the mechanical position indicator (option)
23
16.
Closing the switch compartment
23
17.
Enclosure protection IP 68 (option)
24
18.
Applications in Ex Zone 22 (Option)
25
19.
Maintenance
26
20.
Lubrication
26
21.
Disposal and recycling
27
22.
Service
27
23.
Spare parts list Multi-turn actuator SA(R) 07.1 - SA(R) 16.1 with plug/ socket connector
30
24.
Spare parts list Multi-turn actuator SA 25.1 - SA 48.1/SAR 25.1 - SAR 30.1
32
25.
Declaration of Conformity and Declaration of Incorporation
34
Index
35
Addresses of AUMA offices and representatives
36

AUMA NORM
1.
Safety instructions
1.1
Range of application
AUMA actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves and ball valves. For other
applications, please consult us. The manufacturer is not liable for any
possible damage resulting from use in other than the designated
applications. Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the
actuators designated use.
1.2
Commissioning
(electrical connection)
During electrical operation, certain parts inevitably carry lethal voltages.

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.
1.3
Maintenance
The maintenance instructions (refer to page 26) must be observed,

otherwise a safe operation of the actuator is no longer guaranteed.
1.4
Warnings and notes
Non-observance of the warnings and notes may lead to serious injuries or

damage. Qualified personnel must be thoroughly familiar with all warnings
and notes in these operation instructions.
Correct transport, proper storage, mounting, and installation, as well as
careful commissioning are essential to ensure a trouble-free and safe
operation.
During operation, the multi-turn actuator warms up and surface
temperatures > 60 C may occur. Check the surface temperature prior to
contact in order to avoid burns.
The following references draw special attention to safety-relevant
procedures in these operation instructions. Each is marked by the
appropriate pictograph.
This pictograph means: Note!
Note marks activities or procedures which have major influence on the
correct operation. Non-observance of these notes may lead to
consequential damage.
This pictograph means: Electrostatically endangered parts!
If this pictograph is attached to a printed circuit board, it contains parts
which may be damaged or destroyed by electrostatic discharges. If the
boards need to be touched during setting, measurement, or for exchange, it
must be assured that immediately before a discharge through contact with
an earthed metallic surface (e.g. the housing) has taken place.
This pictograph means: Warning!
Warning marks activities or procedures which, if not carried out correctly,
can affect the safety of persons or material.
2.
Short description
AUMA multi-turn actuators type SA 07.1 SA 48.1 and SAR 07.1 SAR 30.1
have a modular design. The limitation of travel is realised via limit switches in
both end positions. Torque seating is also possible in both end positions. The
type of seating is determined by the valve manufacturer.
3.

AUMA NORM
Technical data
Table 1: Multi-turn actuator SA 07.1 SA 48.1 / SAR 07.1 SAR 30.1

Multi-turn actuators AUMA NORM require electric controls. AUMA offers the controls AUMA MATIC AM or AUMATIC AC for
the sizes SA(R) 07.1 - SA(R) 16.1. These can also easily be mounted to the actuator at a later date.
Features and functions
Type of duty 1)
Standard:
SA
Short time duty S2 - 15 min
SAR Intermittent duty S4 - 25 %
Option:
SA
Short time duty S2 - 30 min
SAR Intermittent duty S4 -50 %
Intermittent duty S5 - 25 %
Motors
Standard:
3-ph AC asynchronous motor, type IM B9 according to IEC 34
Options:
1-ph AC motor, type IM B14 according to IEC 34
DC shunt motor, type IM B14 according to IEC 34
DC compound motor, type IM B14 according to IEC 34
Special motors
Insulation class
Standard:
F, tropicalized
Option:
H, tropicalized
Motor protection
Standard:
Thermoswitches (NC)
Option:
PTC thermistors (according to DIN 44082)
Supply voltage
Refer to motor nameplate
Self-locking
yes; for output speeds from 4 to 90 rpm and from size SA 35.1 for output speeds from 4 to 22 rpm
Limit switching
Counter gear mechanism for end positions CLOSED and OPEN
for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke)
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)
Torque switching
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
Non-intrusive setting
Magnetic limit and torque transmitter MWG for the sizes SA 07.1 - SA 16.1
(option)
(only possible in combination with actuator controls AUMATIC)
for 1 to 500 turns per stroke or for 10 to 5,000 turns per stroke
Position feedback signal,
Potentiometer or 0/4 20 mA
analogue (options)
For further details see separate data sheet
Torque feedback signal,
Only in combination with magnetic limit and torque transmitter MWG and actuator controls
analogue (option)
AUMATIC
Mechanical position
Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
indicator
Running indication
Blinker transmitter (for SA standard, for SAR option)
Heater in switch
Standard:
self-regulating PTC heater, 5 20 W, 110 250 V DC/AC
compartment
Options:
24 48 V DC/AC or 380 400 V AC
A resistance type heater (5 W, 24 V DC) is installed in the actuator in combination with the
actuator controls AUMA MATIC.
Motor heater (option)
SA(R) 07.1 10.1:
12.5 W
SA(R) 14.1 16.1:
25 W
SA(R) 25.1 30.1:
50 W
SA
35.1 48.1:
50 W
Manual operation
Manual drive for setting and emergency operation, handwheel does not rotate during electrical
operation.
Option:
Handwheel lockable
Electrical connections
Standard:
SA(R) 07.1 16.1: AUMA plug/ socket connector with screw type connection,
SA(R) 25.1 48.1: Control connections on AUMA plug/ socket connector,
motor connection via terminals
Option:
for special motors: Motor connection directly via terminal board at the motor
Threads for cable glands
Standard:
Metric threads
Options:
Pg-threads, NPT-threads, G-threads
Terminal plan
Terminal plan according to commission number included in delivery
Output drive types
A, B1, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drives: AF, AK, AG, IB1, IB3
1) Based on 20 C ambient temperature and at an average load with running torque according to Technical data SA(R).

AUMA NORM
Service conditions
Enclosure protection
according to EN 60 5292)
Corrosion protection
Finish coating
Colour
Ambient temperature 3)
Vibration resistance
according to IEC 60068-2-6
Lifetime4)
Standard:
Options:
IP 67
IP 68
IP 67-DS (Double Sealed)
IP 68-DS (Double Sealed)
(Double Sealed = terminal compartment additionally sealed against interior)
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 atmosphere with high
humidity and high pollutant concentration
KX-G same as KX, however aluminium-free version (outer parts)
Standard:
two-component iron-mica combination
Standard:
silver-grey (DB 701, similar to RAL 9007)
Option:
Other colours are possible on request
Standard:
SA
- 25 C to + 80 C
SAR - 25 C to + 60 C
Options:
SA
- 40 C to + 60 C (low temperature)
- 50 C to + 60 C (extreme low temperature)
- 60 C to + 60 C (extreme low temperature)
- 0 C to +120 C (high temperature)
SAR - 40 C to + 60 C (low temperature)
2 g, for 10 to 200 Hz (only for sizes SA(R) 07.1 SA(R) 16.1 without controls)
Type
Operating cycles (OPENCLOSEOPEN)

with 30 turns per stroke
20,000
15,000
10,000
5,000
SA 07.1 SA 10.1
SA 14.1 SA 16.1
SA 25.1 SA 30.1
SA 35.1 SA 48.1
Type
SAR 07.1 SAR 10.1

SAR 14.1 SAR 14.5
SAR 16.1
SAR 25.1 SAR 30.1
Other information
Reference documents
Starts in
millions
min.
5.0
3.5
3.5
2.5
Number of starts per hours based on S4 - 25 %, for an

expected lifetime of a minimum of operation hours
5,000 h
1,000
700
600
300
10,000 h
500
300
300
250
20,000 h
250
175
175
125
Product description Electric multi-turn actuators SA

Dimension sheets SA(R)
Electrical data sheets SA/SAR
Technical data sheets SA/SAR
2) 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 1-phase AC motors, DC motors, or special motors, the enclosure protection according the name plate applies.
3) Versions with RWG up to max. to + 70 C
4) The lifetime in operation hours (h) 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.

AUMA NORM
..
.
4.
Transport, storage and packaging
4.1
Transport
Fitting the handwheel:
For transport to place of installation, use sturdy packaging.

Do not attach ropes or hooks to the handwheel for the purpose of lifting by
hoist.
If multi-turn actuator is mounted on valve, attach ropes or hooks for the
purpose of lifting by hoist to valve and not to multi-turn actuator.
For transport purposes, handwheels from a diameter of 400 mm are

supplied separately.
.
..
Engage manual operation prior to mounting the handwheel!

If the manual operation is not engaged, damages can occur
at the change-over mechanism.
Engage manual operation (figure A-1):
Manually lift the red change-over lever while slightly turning the shaft back
and forth until manual operation engages. The manual operation is
correctly engaged if the change-over lever can be lifted by approx. 85.
Manual force is sufficient for operating the change-over
lever. It is not necessary to use an extension. Excessive
force may damage the change-over mechanism.
Attach handwheel onto the red change-over lever on shaft (figure A-2).
Secure handwheel using the circlip supplied.
Figure A-1
Figure A-2
85
4.2
Storage
..
..
Store in well-ventilated, dry room.

Protect against floor dampness by storage on a shelf or on
a wooden pallet.
Cover to protect against dust and dirt.
Apply suitable corrosion protection agent to bright surfaces.
If multi-turn actuators are to be stored for a long time (more than 6 months),
in addition, the following points must imperatively be observed :
.
.
Prior to storage: Protect bright surfaces, in particular the output drive parts
and mounting surface, with long-term corrosion protection agent.
Check for corrosion approximately every 6 months. If first signs of
corrosion show, apply new corrosion protection.
After mounting, connect actuator immediately to electrical
system, so that the heater prevents condensation.
4.3
Packaging
Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can
easily be separated and recycled.
We use the following packaging materials: wood, cardboard, paper and PE
foil. For the disposal of the packaging material, we recommend recycling
and collection centres.

AUMA NORM
5.
.
.
Prior to mounting the multi-turn actuator must be checked

for damage. Damaged parts must be replaced by original
spare parts.
After mounting, check multi-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.
Mounting is most easily done with the valve shaft/ gearbox shaft pointing
vertically upward. But mounting is also possible in any other position.
The multi-turn actuator leaves the factory in position CLOSED (limit switch
CLOSED tripped).
Check if mounting flange fits the valve/ gearbox.

Spigot at flanges should be loose fit!
The output drive types B1, B2, B3, or B4 (figure A-3) are delivered with bore
and keyway (usually according to ISO 5210).
Figure A-3
Output drive type B1/ B2
Plug sleeve
Output drive type B3/ B4

Bore with keyway
For output drive type A (figure B-1), the internal thread of the stem nut must
match the thread of the valve stem. If not ordered explicitly with thread, the
stem nut is unbored or with pilot bore when delivered. For finish machining
of stem nut refer to next page.
Check whether bore and keyway match the input shaft of valve/ gearbox.
Thoroughly degrease mounting faces at multi-turn actuator and valve/
gearbox.
Apply a small quantity of grease to input shaft of valve/ gearbox.
Place actuator on valve/ gearbox and fasten. Fasten bolts (quality min. 8.8,
refer to table 2) evenly crosswise.
..
..
Table 2: Fastening torque for bolts

Strength class 8.8
M 8
M 10
M 12
M 16
M 20
M 30
M 36
TA (Nm)
25
50
87
220
420
1,500
2,500

AUMA NORM
Finish machining of stem nut (output drive type A):

Figure B-1
Output drive type A
Stem nut
80.3
80.01/ 80.02
80.2
..
..
..
.
..
The output drive flange does not have to be removed from the actuator.
Remove spigot ring (80.2, figure B-1) from mounting flange.
Take off stem nut (80.3) together with thrust bearing (80.01) and thrust
bearing races (80.02).
Remove thrust bearing and thrust bearing races from stem nut.
Drill and bore stem nut and cut thread.
When fixing in the chuck, make sure stem nut runs true!
Clean the machined stem nut.
Apply Lithium soap EP multi-purpose grease to thrust bearing and races,
then place them on stem nut.
Re-insert stem nut with thrust bearings into the mounting flange. Ensure
that dogs are placed correctly in the slots of the hollow shaft.
Screw in spigot ring until it is firm against the shoulder.
Press Lithium soap EP multi-purpose grease on mineral oil base into the
grease nipple with a grease gun (for quantities, refer to table):
Table 3: Grease quantities for lubricating bearings

Output
drive
Qty1)
A 07.2 A 10.2
1,5 g
2g
A 14.2
A 16.2
A 25.2
A 30.2
A 35.2
A 40.2
A 48.2
3g
5g
10 g
14 g
20 g
25 g
30 g
1) For grease with a density = 0.9 kg/dm
.
..
.
Protection tube for rising valve stem

Protection tubes may be supplied loose. Seal thread with hemp, Teflon
tape, or thread sealing material.
Screw protection tube (1) into thread (figure B-2) and tighten it firmly.
Push down the sealing (2) to the housing.
Check whether cap (3) is available and without damage.
Figure B-2: Protection tube for rising valve stem
1
2

AUMA NORM
6.
Manual operation
Engaging manual operation:
The actuator may be operated manually for purposes of setting and

commissioning, and in case of motor failure or power failure.
Manual operation is engaged by an internal change-over mechanism.
Lift up change-over lever in the centre of the handwheel to approx. 85,

while slightly turning the handwheel back and forth until manual operation
engages (figure C).
Figure C
Figure D
Manual force is sufficient for operating the change-over

lever. It is not necessary to use an extension. Excessive
force may damage the change-over mechanism.
Release change-over lever (should snap back into initial position by spring
action, figure D), if necessary, push it back manually.
Operating the change-over lever while the motor is running
(figure E) can lead to increased wear at the change-over
mechanism.
Figure E
Figure F
Turn handwheel into desired direction (figure F).
Disengaging manual operation: Manual operation is automatically disengaged when the motor is started
again.
The handwheel does not rotate during motor operation.
10

AUMA NORM
7.
7.1
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.
.
..
.
..
.
Figure G-1: Connection

50.0
50.01
51.0
51.01
Check whether type of current, supply voltage, and frequency correspond

to motor data (refer to name plate at motor).
Loosen bolts (50.01) (figure G-1) 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
suitable cable glands are used).
Seal cable entries which are not used with suitable plugs.
Connect cables according to order-related terminal plan.
The terminal plan applicable to the actuator is attached to the handwheel
in a weather-proof bag, together with the operation instructions. In case
the terminal plan is not available, it can be obtained from AUMA (state
commission no., refer to name plate) or downloaded directly from the
Internet (www.auma.com).
Figure G-2: Parking frame (accessory)
A special parking frame (figure G-2) for protection against touching the bare
contacts and against environmental influences is available.
Parking frame
Table 4: Technical data AUMA plug/ socket connectors

Technical data
No. of contacts max.
Marking
Voltage max.
Nominal current max.
Type of customer connection
Cross section max.
Material: Pin/ socket carrier
Contacts
Power terminals1)
6 (3 are used)
U1, V1, W1, U2, V2, W2
750 V
25 A
Screws
6 mm2
Polyamide
Brass (Ms)
Protective earth
1 (leading contact)
according to VDE
Screw for ring lug

6 mm2
Polyamide
Brass (Ms)
Control pins
50 pins/sockets
1 to 50
250 V
16 A
Screws
2.5 mm2
Polyamide
Brass, tin plated or gold plated (option)
1) Suitable for copper wires. For aluminium wires it is necessary to contact AUMA.
From size SA(R) 25.1, the motor connection is realised via a separate terminal board
11

AUMA NORM
7.2
Motor connection for the sizes SA(R) 25.1/SAR 30.1 SA 48.1.

From the size SA(R) 25.1, the power for the motor is connected to separate
terminals. For this, the cover at the motor connection compartment has to
be removed.
The control contacts are connected to the AUMA plug/ socket connector.
Cross section motor terminals:
16 mm to 70 mm, depending on the connection power
Figure G-3: Connection to SA(R) 25.1
AUMA plug/ socket connector
7.3
Cover motor connection compartment
Motor connection for

special motors
For versions with special motors (e.g. two-pole motors), the connection is
realised directly at the motor (figure G-4).
Figure G-4: Connection special motor
7.4
Delay time
The delay time is the time from the tripping of the limit or torque switches to
the motor power being removed. To protect the valve and the actuator, we
recommend a delay time < 50 ms. Longer delay times are possible provided
the output speed, output drive type, valve type, and the type of installation
are taken into consideration.
We recommend to switch off the corresponding contactor directly by the limit
or torque switch.
7.5
Controls made by AUMA
In case the required reversing contactors are not to be installed in the

control cabinet, the controls AUMA MATIC or AUMATIC for the sizes SA(R)
07.1 SA(R) 16.1 can be easily mounted to the actuator at a later date.
For enquiries and more information, please state our commission no. (refer
to actuator name plate).
7.6
Heater
AUMA multi-turn actuators have a heater installed as standard. To prevent

condensation, the heater must be connected.
7.7
Motor protection
In order to protect against overheating and impermissibly high temperatures

at the actuator, PTC thermistors or thermoswitches are embedded in the
motor winding. The thermoswitch is tripped as soon as the max. permissible
winding temperature has been reached.
Failure to integrate PTC thermistors or thermoswitches into the control
circuit voids the warranty for the motor.
7.8
12
Remote position transmitter
For the connection of remote position transmitters (potentiometer, RWG)

screened cables must be used.

AUMA NORM
7.9
Limit and torque switches

Only the same potential can be switched on the two circuits (NC/ NO
contact) of a limit or torque switch. If different potentials are to be switched
simultaneously, tandem switches are required.
To ensure correct signalisation, the leading contacts of the tandem switches
must be used for that purpose and the lagging contacts for switching off.
Figure G-5
BK
RD
I Single switch
Mechanical
lifetime = 2 x 106 starts
BK
RD
Table 5: Technical data for limit and torque switches
NO NC
NC NO
Type of current
DSR 1 / DL 1
WSR 1 / WL 1
BK 2
BK 2
RD 2
RD 2
BK
BK
RD
RD
II Tandem switch
1-phase AC
(ind. load) cos phi = 0,8
DC
(resistive load)
with gold plated
contacts
Current
30 V
Switch rating Imax

125 V
250 V
5A
5A
5A
2A
0,5 A
0.4 A
min. 5 V, max. 50 V
min. 4 mA, max. 400 mA
DSR / DL
WSR / WL
7.10 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

AUMA NORM
8.
Opening the switch

compartment
To be able to carry out the following settings (clauses 9. to 15.), the switch
compartment must be opened and, if installed, the indicator disc must be
removed.
These settings are only valid for clockwise closing, i.e. driven shaft turns
clockwise to close the valve.
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.
8.1
Removing the switch

compartment cover
Remove 4 bolts and take off the cover at the switch compartment
(figures H) .
Fig. H-1: Cover with indicator glass
Fig. H-2: Cover without indicator glass
Bolts
8.2
Pulling off the indicator disc (option)

If installed, pull off indicator disc (figure J). Open end wrench
(approx. 14 mm) may be used as lever.
Figure J: Pulling off the indicator disc
RSD
RDW
Indicator disc
14

AUMA NORM
9.
Setting the limit switching
9.1
Setting the end position CLOSED (black section)
..
.
Turn handwheel clockwise until valve is closed.

After having reached the end position, turn back handwheel by
approximately a turn (overrun). During test run, check overrun and, if
necessary, correct setting of the limit switching.
Press down and turn setting spindle A (figure K-1) 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.
Figure K-1: Control unit
B
E
C
F
A
9.2
9.3
.
.
Setting the end position OPEN (white section)
Checking the limit switches
Turn handwheel counterclockwise until valve is open, then turn back by

approximately a turn.
Press down and turn setting spindle D (figure K-1) 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
The red test buttons T and P (figure K-1) 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 (WL) triggers limit switch OPEN.
15

AUMA NORM
10. Setting the DUO limit switching (option)

Any application can be switched on or off via the two intermediate position
switches.
For setting, the switching point (intermediate position) must
be approached from the same direction as later during
electrical operation.
..
10.1 Setting the direction CLOSE (black section)

Move valve to desired intermediate position.
Press down and turn setting spindle G (figure K-2) with screw driver
(5 mm) in direction of arrow, thereby observe pointer H.
While a ratchet is felt and heard, the pointer H moves 90 every time.
When pointer H is 90 from mark C, continue turning slowly. When pointer
H has reached the mark C, stop turning and release setting spindle. If you
Figure K-2: Control unit
F
L
H
G
..
10.2 Setting the direction OPEN (white section)
10.3 Checking the DUO switches
The red test buttons T and P (Figure K-2) are used for manual operation of
DUO limit switches.
.
.
16
Move valve to desired intermediate position.

Press down and turn setting spindle K (figure K-2) with screw driver
(5 mm) in direction of arrow, thereby observe pointer L.
While a ratchet is felt and heard, the pointer L moves 90 every time.
When pointer L is 90 from mark F, continue turning slowly. When pointer L
has reached the mark F, stop turning and release setting spindle. If you
Turning T in direction of the arrow TSC (DSR) triggers DUO limit switch CLOSED.
The torque switch CLOSED is actuated at the same time.
Turning P in direction of the arrow TSO (DL) triggers DUO limit switch OPEN.
The torque switch OPEN is actuated at the same time.

AUMA NORM
11. Setting the torque switching

11.1 Setting
..
The set torque must suit the valve!

This setting should only be changed with the consent of
the valve manufacturer!
Figure L: Torque switching heads

Setting CLOSED
..
.
Setting OPEN
Loosen both lock screws O at the torque dial (figure L).

Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm).
Example:
Figure L shows the following setting:
3.5 da Nm = 35 Nm for direction CLOSE
4.5 da Nm = 45 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.
11.2 Checking the torque switches

The red test buttons T and P (figure K-2) 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 (DL) 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.
17

AUMA NORM
12. Test run

12.1 Check direction of rotation
.
.
If provided, place indicator disc on shaft.

The direction of rotation of the indicator disc (figure M-1) indicates the
direction of rotation of the output drive.
If there is no indicator disc, the direction of rotation can also be observed
on the hollow shaft. For this, remove screw plug (no. 27) (figure M-2).
Figure M-1: Indicator disc

CLOSED
Figure M-2: Opening the hollow shaft

OPEN
27
S1/S2
.
.
Move actuator manually to intermediate position or to sufficient distance

from end position.
Switch on actuator in direction CLOSE and observe the direction of
rotation:
If the direction of rotation is wrong, switch off immediately
Then, correct phase sequence at motor connection. Repeat test run.
Table 6:
Direction of rotation of the indicator disc:
counterclockwise
Direction of rotation of the hollow shaft:
clockwise
12.2 Check limit switching
..
.
correct
correct
Move actuator manually into both end positions of the valve.

Check if 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 from page 15.
If no other options (clauses 13. to 15.) require setting:

Close switch compartment (see page 23, clause 16.).
18

AUMA NORM
13. Setting the potentiometer (option)
..
.
.
For remote indication
Move valve to end position CLOSED.

If installed, pull off indicator disc.
Turn potentiometer (E2) clockwise until stop is felt.
End position CLOSED corresponds to 0 %, end position OPEN to 100 %.
Turn potentiometer (E2) back a little.
Due to the ratio of the reduction gearings for the position
transmitter the complete resistance range is not always
utilized for the whole travel. Therefore, an external
possibility for adjustment (setting potentiometer) must be
provided.
Perform fine-tuning of the zero point at external setting potentiometer (for
remote indication).
Figure N: Control unit
E2
19

AUMA NORM
14. Setting the electronic position transmitter RWG (option)

For remote indication or external controls
After mounting the multi-turn actuator to the valve, check setting by
measuring the output current (see clause 14.1 or 14.2) and re-adjust, if
necessary.
Table 7: Technical data RWG 4020

Terminal plans
KMS TP_ _ 4 / _ _ _
3- or 4-wire system
Output current
Power supply
max. input
current
max. load
Ia
Uv
I
RB
0 20 mA, 4 20 mA
24 V DC, 15 %
smoothed
24 mA at 20 mA
output current
600
KMS TP _ 4 _ / _ _ _
KMS TP _ 5 _ / _ _ _
2-wire system
4 20 mA
14 V DC + (I x RB),
max. 30 V
20 mA
(Uv - 14 V) / 20 mA
The position transmitter board (figure P-1) is located under the cover plate
(figure P-2).
Figure P-1: Position transmitter board
20

AUMA NORM
..
..
14.1 Setting for 2-wire system 4 - 20 mA and 3-/ 4-wire system 0 20 mA
..
Connect voltage to electronic position transmitter.

Connect ammeter for 0 20 mA to measuring points (figure P-2).
The circuit (external load) must be connected (max. load
RB), or the appropriate poles at the terminals (refer to
terminal plan) must be linked, otherwise no value can be
measured.
Turn potentiometer (E2) clockwise to the stop.
Figure P-2
0 (0/4 mA)
max. (20 mA)
Cover plate
E2
Meas. point (+)
0/4 20 mA
..
..
.
Meas. point ()
0/4 20 mA
Turn potentiometer 0 clockwise until output current starts to increase.

Turn potentiometer 0 back until the following value is reached:
for 3- or 4-wire system:
approx. 0.1 mA
for 2-wire system:
approx. 4.1 mA.
This ensures that the signal remains above the dead and live zero point.
Move valve to end position OPEN.
Set potentiometer max. to end value 20 mA.
Approach end position CLOSED anew and check minimum value (0.1 mA
or 4.1 mA). If necessary, correct the setting.
If the maximum value cannot be reached, the selection of the
reduction gearing must be checked.
21

AUMA NORM
..
..
14.2 Setting the 3-/ 4- wire system 4 20 mA

Connect voltage to electronic position transmitter.
Connect ammeter for 0 20 mA to measuring points (figure P-2).
..
The circuit (external load) must be connected (max. load

RB), or the appropriate poles at the terminals (refer to
terminal plan) must be linked, otherwise no value can be
measured.
Turn potentiometer (E2) clockwise to the stop.
Fig. P-2
0 (0/4 mA)
max. (20 mA)
Cover plate
E2
Meas. point (+)
0/4 20 mA
Meas. point ()
0/4 mA 20 mA
..
..
..
.
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.
22

AUMA NORM
15. Setting the mechanical position indicator (option)
..
.
..
Place indicator disc on shaft.

Turn lower indicator disc (figure Q1) until symbol
CLOSED is in
alignment with the mark on the cover (figure Q-2).
Move actuator to end position OPEN.
Hold lower indicator disc CLOSED in position and turn upper disc with
symbol
OPEN until it is in alignment with the mark on the cover.
Figure Q-1:
Figure Q-2:
Indicator disc
Mark
Indicator disc rotates by approximately 180 to 230at full travel from OPEN
to CLOSED or vice versa.
A suitable reduction gearing was installed in our factory. If the turns per
stroke are changed at a later date, the reduction gearing may have to be
exchanged, too.
16. Closing the switch compartment
..
..
Clean sealing faces of housing and cover

Check whether O-ring is in good condition.
Apply a thin film of non-acidic grease to the sealing faces.
Replace cover on switch compartment and fasten bolts evenly crosswise.
After commissioning, check for damage to paint finish of
multi-turn actuator. If damage to paint-finish has occurred
after mounting, it has to be touched up to avoid corrosion.
23

AUMA NORM
17. Enclosure protection IP 68 (option)

Definition
According to DIN EN 60 259, the conditions for meeting the requirements of

enclosure protection IP 68 are to be agreed between manufacturer and
user.
AUMA actuators and controls in enclosure protection IP 68 meet the
following requirements according to AUMA:
Duration of submersion in water max. 72 hours
Head of water max. 6 m
Up to 10 operations during submersion
Modulating duty is not possible during submersion
..
..
Enclosure protection IP 68 refers to the interior of the actuators (motor,

gearing, switch compartment, control, and terminal compartment).
For multi-turn actuators, the following has to be observed:
When using output drive types A and AF (stem nut), it cannot be prevented
that water enters the hollow shaft along the valve stem during submersion.
This leads to corrosion. The water also enters the thrust bearings of output
drive type A, causing corrosion and damage of the bearings. The output
drive types A and AF should therefore not be used.
Inspection
Cable glands
Commissioning
After submersion
AUMA actuators and controls in enclosure protection IP 68 undergo a

routine testing for tightness in the factory.
.
.
.
.
.
..
..
..
When commissioning, the following should be observed:

Sealing faces of housing and covers must be clean
O-rings of the covers must not be damaged
A thin film of non-acidic grease should be applied to sealing faces
Covers should be tightened evenly and firmly
24
For the entries of the motor and control cables appropriate, cable glands
in enclosure protection IP 68 must be used. The size of the cable glands
must be suitable for the outside diameter of the cables, refer to
recommendations of the cable gland manufacturers.
As standard, actuators and controls are delivered without cable glands.
For delivery, the threads are sealed with plugs in the factory.
When ordered, cable glands can also be supplied by AUMA at an
additional charge. For this, it is necessary to state the outside diameter of
the cables.
The cable glands must be sealed against the housing at the thread with an
O-ring.
It is recommended to additionally apply a liquid sealing material (Loctite or
similar).
Check actuator.
In case of ingress of water, dry actuator correctly and check for proper
function.
During repair, commissioning, and maintenance of the multi-turn actuators

for ZONE 2, special care is imperatively required in order to guarantee the
explosion protection of the actuator.

AUMA NORM
18. Applications in Ex Zone 22 (Option)

Multi-turn actuators of type range SA 07.1 SA 16.1/SAR 07.1 SAR 16.1
in versions AUMA NORM basically meet the requirements for applications in
hazardous dust areas of ZONE 22, in compliance with the ATEX directive
94/9/EC.
The actuators are designed to enclosure protection IP 67 or IP 68 and fulfil
the requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for
use in presence of combustible dust hazards, requirements for electrical
equipment of category 3 protected by enclosures.
To comply with all requirements of EN 50281-1-1: 1998, the following points
must imperatively be observed:
.
.
.
.
.
.
.
.
In compliance with the ATEX directive 94/9/EC, the multi-turn actuators

must be equipped with an additional identification II3D IP6X T150 C.
The maximum surface temperature of actuators based on an ambient
temperature of +40 C in accordance with EN 50281-1-1 section 10.4 is
150 C. In accordance with section 10.4, an increased dust deposit on the
equipment was not considered for the determination of the max. surface
temperature.
The correct connection of the thermoswitches or the PTC thermistors, as
well as the fulfilment of the type of duty and the technical data are
prerequisites for compliance with the maximum surface temperature of the
multi-turn actuators.
The connection plug may only be plugged in or pulled out when the mains
are switched off.
The cable glands used have also to meet the requirements of category
II3D and must at least comply with enclosure protection IP 67.
The actuators must be connected by means of an external ground
connection (accessory part) to the potential equalization or integrated into
a grounded piping system.
The screw plug (part no. 27) or the protection tube with cap (part nos.
160.1 and 160.2) for sealing the hollow shaft must imperatively be
mounted to guarantee the combustible dust hazard protection.
As a general rule, the requirements of EN 50281-1-1 must be respected in
dust hazardous locations. During commissioning, service, and
maintenance, respective special care as well as qualified and trained
personnel is required for the safe operation of multi-turn actuators.
25

AUMA NORM
19. Maintenance
After maintenance, check multi-turn actuator for damage to paint finish. If

damage to paint-finish has occurred, it has to be touched up to avoid
corrosion. Original paint in small quantities can be supplied by AUMA.
AUMA multi-turn actuators require low-level 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, 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.
.
.
.
We recommend additionally:
20. Lubrication
..
..
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 actuator and valve/ gearbox for tightness. If required, tighten
applying the torques given in table 2, page 8.
For multi-turn actuators with output drive type A: at intervals of approx. 6
months from commissioning press in Lithium soap EP multi-purpose
grease on mineral oil base at the grease nipple with grease gun (quantity
see table 3, page 9).
The gear housing is filled with lubricant in the factory.

A grease change is recommended after the following operation time:
If rarely operated, after 10 12 years
If operated frequently, after 6 8 years
Lubrication of the valve stem must be done separately.
26

AUMA NORM
21. Disposal and recycling

AUMA actuators have an extremely long lifetime. However, they have to be
replaced at one point in time.
The actuators have a modular design and may therefore easily be
disassembled, separated, and sorted according to materials, i.e.:
..
..
.
.
.
electronic scrap
various metals
plastics
greases and oils
The following generally applies:

Collect greases and oils during disassembly. As a rule, these substances
are hazardous to water and must not be released into the environment.
See disassembled material to a sound disposal or to separate recycling
according to materials.
Observe the national regulations for waste disposal.
22. Service
AUMA offers extensive services such as maintenance and inspection for

actuators. Addresses of AUMA offices and representatives can be found on
page 36 and on the Internet (www.auma.com).
27

AUMA NORM
Notes
28

AUMA NORM
Notes
29
30
S2
70.0
79.0
156.0
70.1
54.0
60.0
49.0
106.0
105.0
100
107
1.0
25.0
019
020
24.0 / 23.0
22.0
52.0
51.0
18
19.0
17.0
S1 / S2
B1 / C
053
S2
24
- Actuator type
- Commission number
- Works number
- Protection type
Torque range
in CLOSE/ OPEN
- Lubricant
- Temperature range
61.0
20.0
57.0
56.0
53.0
59.0
S1 / S2
S2
S2
15.0 Sample name plate
S1 / S2
SA 07.1 SA 14.1
SAR 07.1 SAR 14.1
SA16.1
SAR 16.1
S2 S2
79.0
S2
S2
S2
2.0
3.0
5.32
5.7
S2
5.12
S1 / S2
39
S1 / S2
27
58.0
55.0
50.0
160.1
160.2
5.0
S2
80.001
80.3
80.001
80.0
5.37
5.8
151.0
152.1
152.2
90.001
90.001
9.0
90.0
S2
10.0
153.5
85.001
85.001
S2
153.0
B3 / B4 / E
153.3
153.1
153.2
85.0
30.0
14
012
155.0

AUMA NORM
23. Spare parts list Multi-turn actuator SA(R) 07.1 - SA(R) 16.1 with plug/ socket connector

AUMA NORM
No.
Type
Designation
012
Notched pin
019
Cheese head screw
020
Clamping washer
053
No.
Type
Designation
58.0
59.0 1)
Wire for protective earth

Pin for motor and thermoswitch
in motor plug
60.0
Control unit assly. (but without torque head,

without switches)
Countersunk screw
1.0
Housing assly.
2.0
Flange, bottom assly.
61.0
Torque switching head
3.0
Hollow shaft assly. (without worm wheel)
70.0
5.0
Worm shaft assly.
5.12
Grub screw
70.1 1)
Motor
Motor pin carrier
(without pins)
5.32
Coupling pin
79.0 2)
5.37
Pull rod assly.
5.7
Motor coupling
80.0 3)
Planetary gearing for motor drive assly.

Output drive form A assly.
(without thread in stem nut)
5.8
Manual drive coupling assly.
80.0013
Thrust bearing set
Worm wheel
80.3 3)
Stem nut form A (without thread)
3)
Output drive B3
Snap ring
Output drive D
9.0
Planetary gear assly. for manual drive
85.0
10.0
Retaining flange assly.
85.0013)
3)
14
Change-over lever
90.0
15.0
Cover for switch compartment assly.
90.0013)
17.0
Torque lever assly.
18
Gear segment
19.0
Crown wheel assly.
20.0
Swing lever assly.
22.0
23.0
100
Snap ring
Switch for limit/ torque switching
(including pins at wires)
105.0
Blinker transmitter including pins at wires

(without impulse disc and insulation plate)
Drive pinion II for torque switching assly.
106.0
Stud bolt for switches
Drive wheel for limit switching assly.
107
Spacer
Heater
24
Drive wheel for limit switching
151.0
24.0
Intermediate wheel for limit switching assly.
152.1 3)
Potentiometer (without slip clutch)
25.0
Locking plate
152.2 3)
Slip clutch for potentiometer
3)
153.1 3)
RWG assly.
Potentiometer for RWG
(without slip clutch)
153.0
27
Screw plug
30.0
Handwheel with ball handle assly.
39
Screw plug
49.0 1)
Motor plug, socket assly.
153.2 3)
Slip clutch for RWG
50.0
Cover assly.
153.3 3)
Electronic board RWG
3)
51.0
Socket carrier assly. (with sockets)
153.5
Wires for RWG
52.0
Pin carrier (without pins)
155.0 3)
Reduction gearing
53.0
Socket for control
156.0 3)
Mechanical position indicator
3)
Protection tube(without cap)
Cap for stem protection tube
Seal kit, small
Seal kit, large
54.0
Socket for motor
160.1
55.0
Socket for protective earth
160.2 3)
56.0
Pin for control
S1
57.0
Pin for motor
S2
1) SA 16.1 with output speeds of 32 to 180 rpm or SAR 16.1 with output speeds of 32 and 45 rpm without
plug/ socket connector; motor directly wired to pin carrier (No. 52.0) .
2) not available for all output speeds
3) not included in basic equipment
31

AUMA NORM
Sample name plate
32
Torque range
in CLOSE/ OPEN
- Lubricant
- Temperature range
- Works number
- Protection type
- Actuator type
- Commission number
24. Spare parts list Multi-turn actuator SA 25.1 - SA 48.1/SAR 25.1 - SAR 30.1

AUMA NORM
Notes:
When placing orders for spare parts, it is essential to mention type of actuator and our commission number (refer to
actuator name plate). Delivered spare parts may slightly vary from the representation in these instructions.
No.
Type
Designation
No.
Type
Designation
1.026
Quad ring / radial seal
54.0
Socket for motor
1.038
O-ring
55.0
Socket for protective earth
1.1
Housing assly.
56.0
Pin for control
1.17
Torque lever assly.
57.0
Pin for motor
1.19
Crown wheel assly.
58.0
Wire for protective earth
1.22
Drive pinion II for torque switching assly.
61.0
1.23
80.0 *
1.24
Drive wheel for limit switching assly.

Intermediate wheel for limit switching
assly.
Torque switching head

Output drive form A assly.
(without thread in stem nut)
80.001*
Thrust bearing set
1.25
Locking plate
80.3 *
Stem nut form A (without thread)
1.27
Screw plug
85.0 *
Output drive form B3 assly.
1.28
Bearing bush
85.001*
2.58
Motor
2.59
Planetary gear assly. for motor drive
Drive shaft assly.
3.05
Dowel pin
3.11
3.6
100
Snap ring
Switch for limit/ torque switching
(including pins at wires)
105
Blinker transmitter including pins at wires

(without impulse disc and insulation plate)
Pull rod assly.
106.0
Stud bolts for switches
Worm wheel assly.
107
Spacer
3.7
Motor coupling
151.0
Heater
3.8
Manual drive coupling assly.
152.1 *
Potentiometer (without slip clutch)
4.2
Flange, bottom assly.
152.2 *
Slip clutch for potentiometer
4.3
Hollow shaft assly.
153.0 *
RWG assly.
Planetary gear assly. for manual drive
153.1 *
Potentiometer for RWG (without slip clutch)
5.1
Mounting flange
153.2 *
Slip clutch for RWG
5.2
Hand wheel shaft assly.
153.3 *
Printed board for RWG
Swing lever assly
155.0 *
Reduction gearing
7.012
Notched pin
156.0 *
7.14
Change-over lever
160.1 *
Protection tube (without cap)
7.50
160.2 *
Cap
S1
Seal kit (small)
S2
Seal kit (large)
8.36
Handwheel with ball handle assly.

Control unit assly. (but without torque
head, without switches)
8.37
Switch compartment cover
9.33
Terminals for motor connection
9.51
9.55
Protective earth connection

Cover for motor connection compartment
assly.
50.0
Plug cover assly.
51.0
Socket carrier assly. (with sockets)
52.0
Pin carrier (without pins)
53.0
Socket for control
not available for all output speeds

* not included in basic equipment
33

AUMA NORM
25. Declaration of Conformity and Declaration of Incorporation
34

AUMA NORM
Index
C
Corrosion protection
D
Declaration of Conformity
Declaration of Incorporation
DUO limit switching
7
34
34
16
E
11
Electronic position transmitter RWG
20
2-wire system
21
3-/ 4-wire system
22
Enclosure protection IP 68
24
F
Finish machining of stem nut
H
Handwheel
Heater
I
Indicator disc
Internet
L
Limit switches
Limit switching
Lubrication
Information also available

on the Internet
9
10
12
23
35
M
Maintenance
Manual operation
Motor protection
O
Output drive types
P
Packaging
Position indicator
Position transmitter RWG
Potentiometer
Protection tube
PTC thermistors
4
10
23
12
8
8
T
Tandem switches
Technical data
Test run
Thermoswitches
Torque setting
Transport
Tripping torque
13
5
18
12
17
7
17
7
23
20
19
9
12
R
Remote indication
19,20
S
Safety instructions
Service
Spare parts list
Storage
4
27
30,32
7
13
15,16
26
Terminal plan, inspection records, and further actuator information

can be downloaded directly from the Internet by entering the order no.
or comm no. (refer to name plate).
Our website: http://www.auma.com
35
Europe
AUMA Riester GmbH & Co. KG
Factory Mllheim
DE-79373 Mllheim
Tel +49 7631 809 - 0
riester@auma.com
www.auma.com
Factory Ostfildern-Nellingen
DE-73747 Ostfildern
Tel +49 711 34803 - 0
riester@wof.auma.com
Service Centre Cologne
DE-50858 Kln
Tel +49 2234 2037 - 9000
Service@sck.auma.com
Service Centre Magdeburg
DE-39167 Niederndodeleben
Tel +49 39204 759 - 0
Service@scm.auma.com
AUMA Armaturenantriebe GmbH
AT-2512 Tribuswinkel
Tel +43 2252 82540
office@auma.at
www.auma.at
AUMA (Schweiz) AG
CH-8965 Berikon
Tel +41 566 400945
RettichP.ch@auma.com
AUMA Servopohony spol. s.r.o.
CZ-10200 Praha 10
Tel +420 272 700056
auma-s@auma.cz
www.auma.cz
OY AUMATOR AB
FI-02270 Espoo
Tel +35 895 84022
auma@aumator.fi
AUMA France
FR-95157 Taverny Cdex
Tel +33 1 39327272
stephanie.vatin@auma.fr
www.auma.fr
AUMA ACTUATORS Ltd.
GB- Clevedon North Somerset BS21 6QH
Tel +44 1275 871141
mail@auma.co.uk
www.auma.co.uk
AUMA ITALIANA S.r.l. a socio unico
IT-20023 Cerro Maggiore (MI)
Tel +39 0331 51351
info@auma.it
www.auma.it
AUMA BENELUX B.V.
NL-2314 XT Leiden
Tel +31 71 581 40 40
office@benelux.auma.com
www.auma.nl
AUMA Polska Sp. z o.o.
PL-41-310 Dabrowa Grnicza
Tel +48 32 26156 68
R.Ludzien@auma.com.pl
www.auma.com.pl
OOO Priwody AUMA
RU-141400 Moscow region for mail: 124365 Moscow
a/ya 11
Tel +7 495 221 64 28
aumarussia@auma.ru
www.auma.ru
ERICHS ARMATUR AB
SE-20039 Malm
Tel +46 40 311550
info@erichsarmatur.se
www.erichsarmatur.se
GRNBECH & SNNER A/S
DK-2450 Kbenhavn SV
Tel +45 33 26 63 00
GS@g-s.dk
www.g-s.dk
IBEROPLAN S.A.
ES-28027 Madrid
Tel +34 91 3717130
iberoplan@iberoplan.com
D. G. Bellos & Co. O.E.
GR-13671 Acharnai Athens
Tel +30 210 2409485
info@dgbellos.gr
SIGURD SRUM A. S.
NO-1301 Sandvika
Tel +47 67572600
post@sigurd-sorum.no
INDUSTRA
PT-2710-297 Sintra
Tel +351 2 1910 95 00
jpalhares@tyco-valves.com
MEGA Endstri Kontrol Sistemieri Tic. Ltd. Sti.
TR-06460 vecler Ankara
Tel +90 312 472 62 70
megaendustri@megaendustri.com.tr
CTS Control Limited Liability Company
UA-02099 Kiyiv
Tel +38 044 566-9971, -8427
v_polyakov@cts.com.ua
Africa
AUMA South Africa (Pty) Ltd.
ZA-1560 Springs
Tel +27 11 3632880
aumasa@mweb.co.za
A.T.E.C.
EG- Cairo
Tel +20 2 3599680 - 3590861
atec@intouch.com
America
AUMA ACTUATORS INC.
US-PA 15317 Canonsburg
Tel +1 724-743-AUMA (2862)
mailbox@auma-usa.com
www.auma-usa.com
AUMA Chile Respresentative Office
CL- Buin
Tel +56 2 821 4108
aumachile@adsl.tie.cl
LOOP S. A.
AR-C1140ABP Buenos Aires
Tel +54 11 4307 2141
contacto@loopsa.com.ar
Asvotec Termoindustrial Ltda.
BR-13190-000 Monte Mor/ SP.
Tel +55 19 3879 8735
atuador.auma@asvotec.com.br
TROY-ONTOR Inc.
CA-L4N 5E9 Barrie Ontario
Tel +1 705 721-8246
troy-ontor@troy-ontor.ca
MAN Ferrostaal de Colombia Ltda.
CO- Bogot D.C.
Tel +57 1 401 1300
dorian.hernandez@manferrostaal.com
www.manferrostaal.com
PROCONTIC Procesos y Control Automtico
EC- Quito
Tel +593 2 292 0431
info@procontic.com.ec
IESS DE MEXICO S. A. de C. V.
MX-C.P. 02900 Mexico D.F.
Tel +52 55 55 561 701
informes@iess.com.mx
Corsusa S.A.C.
PE- Miralflores - Lima
Tel +511444-1200 / 0044 / 2321
corsusa@corsusa.com
www.corsusa.com
PASSCO Inc.
PR-00936-4153 San Juan
Tel +18 09 78 77 20 87 85
Passco@prtc.net
Suplibarca
VE- Maracaibo Estado, Zulia
Tel +58 261 7 555 667
suplibarca@intercable.net.ve
Asia
AUMA Actuators (Tianjin) Co., Ltd.
CN-300457 Tianjin
Tel +86 22 6625 1310
mailbox@auma-china.com
www.auma-china.com
AUMA (INDIA) PRIVATE LIMITED
IN-560 058 Bangalore
Tel +91 80 2839 4655
info@auma.co.in
www.auma.co.in
AUMA JAPAN Co., Ltd.
JP-210-0848 Kawasaki-ku, Kawasaki-shi Kanagawa
Tel +81 44 329 1061
mailbox@auma.co.jp
AUMA ACTUATORS (Singapore) Pte Ltd.
SG-569551 Singapore
Tel +65 6 4818750
sales@auma.com.sg
www.auma.com.sg
Al Ayman Industrial. Eqpts
AE- Dubai
Tel +971 4 3682720
auma@emirates.net.ae
PERFECT CONTROLS Ltd.
HK- Tsuen Wan, Kowloon
Tel +852 2493 7726
joeip@perfectcontrols.com.hk
DW Controls Co., Ltd.
KR-153-803 Seoul Korea
Tel +82 2 2113 1100
sichoi@actuatorbank.com
www.actuatorbank.com
AL-ARFAJ Eng. Company W. L. L.
KW-22004 Salmiyah
Tel +965 4817448
arfaj@qualitynet.net
Petrogulf W.L.L
QA- Doha
Tel +974 4350 151
pgulf@qatar.net.qa
Sunny Valves and Intertrade Corp. Ltd.
TH-10120 Yannawa Bangkok
Tel +66 2 2400656
sunnyvalves@inet.co.th
www.sunnyvalves.co.th/
Top Advance Enterprises Ltd.
TW- Jhonghe City Taipei Hsien (235)
Tel +886 2 2225 1718
support@auma-taiwan.com.tw
www.auma-taiwan.com.tw
Australia
BARRON GJM Pty. Ltd.
AU-NSW 1570 Artarmon
Tel +61 294361088
info@barron.com.au
www.barron.com.au
2006-07-19

Postfach 1362
D - 79373 Mllheim
Tel +49 (0)7631/809-0
Fax +49 (0)7631/809 1250
riester@auma.com
www.auma.com

Postfach 1151
D - 73747 Ostfildern
Tel +49 (0)711 / 34803 0
Fax +49 (0)711 / 34803 34
riester@wof.auma.com
www.auma.com
Certificate Registration No.

12 100/104 4269
For detailed information about AUMA products, refer to the Internet:
www.auma.com
Y000.001/003/en/2.05
INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

FOR HP 111 / HP 114 SERIES
EBRO HIGH PERFORMANCE BUTTERFLY VALVES
DN 50 - 600
CONTENTS:
1. SPECIFICATION
2. NOTES
3. SAFETY INSTRUCTIONS
4. INSTALLATION OF BUTTERFLY VALVE
5. DISMOUNTING OF BUTTERFLY VALVE
6. MAINTENANCE INSTRUCTIONS:
6.1
Replacing the PTFE (Teflon) shaft seal (item 16)
6.2
Replacing the graphite shaft seal (with metal seat item 16)
6.3
Replacing the PTFE (Teflon) sealing ring (item 5)
6.4
Replacing the metal sealing ring (item 5)
7. DISMANTLING OF BUTTERFLY VALVE

8. REFITTING OF DISMANTLED BUTTERFLY VALVE
9. DRAWINGS AND PARTS LIST
10. INSTALLATION INSTRUCTIONS
11. PRESSURE/TEMPERATURE DIAGRAM
HIGH PERFORMANCE VALVE HP111/114

1. SPECIFICATION
HP-series fittings are high performance butterfly valves with double-eccentric,
bearing-mounted disc. Absolutely tight sealing in both flow directions.
These butterfly valves are designed for use with DIN or ANSI standard flanges
and with seals conforming to DIN 2690 or ANSI B16.21.
2. NOTES
The purpose of this manual is to allow qualified technicians to install and
service EBRO high performance butterfly valves and also to ensure their
trouble-free operation.
Butterfly valves should not be removed from the original packaging before
the point of installation.
Butterfly valves should be stored in a dry and dust-free place.
If stored correctly, no special preservation measures are required.
Before installing new pipe systems, all tubes should be flushed out prior to
fitting the butterfly valves. This is to prevent solid objects such as swarf,
welding beads or rust particles damaging the valve seat.
3. SAFETY INSTRUCTIONS
Installation, dismantling and repair work should be carried out by properly
trained and qualified technicians only.
Before starting work, ensure that the person in charge shuts off the affected
section of piping and leaves the pipe connections free of pressure.
Actuators should be properly disconnected (disconnect, dismantle drive
connections and secure).
Never pressurise any butterfly valve that is not equipped with a hand lever or
drive device.
Never dismantle a hand lever or drive device with the unit under pressure. The
double-eccentric bearing mounted design of the disc means that the disc will
tend to open if the stem is located on the non-pressurized side.
Actuators must be constantly air-supply pressurized. Manual gear have to be
self-locking.
For your own safety, always wear protective clothing and use equipment
specified for the items being handled.
Butterfly valves are custom-manufactured to carry out specific tasks and
should therefore be used only for the purposes for which they are designed.
4. INSTALLATION OF BUTTERFLY VALVE

The butterfly valve seals absolutely tight in either directions. However, in order
to ensure minimum wear and actuation torque, we recommend the
installation with the locking ring on the high-pressure side (the shaft is on the
low-pressure side). This installation configuration is essential in the case of an
HP 114 type butterfly valve fitted with a single flange (e.g. as terminal fitting).
FOLLOW THE INSTALLATION INSTRUCTIONS!
1. Check the sealing point of the butterfly valve. If the valve is completely
shut, the disc should be parallel to the mating surface of the flange.
Important: When setting the open/shut end stops, use only the adjusting
screws of the actuator or hand lever.
Never use the integral cam in the interior of the valve body as an end stop
for adjustment.
2. Ensure that the hand lever or actuator is installed in such a way as to
cause the butterfly valve to turn anti-clockwise when it opens.
3. Ensure that the flange clearance corresponds to the installation length of
the butterfly valve.
4. Install the butterfly valve with the flange seals between the flanges,
ensuring that both butterfly valve and seals are centred relative to the
flange.
Use flange seals that comply with DIN2690 and/or ANSI B16.21, with a
thickness of approx. 1.5-2.0 mm. Never use thick rubber seals, as these
affect the sealing action of the butterfly valve.
5. Working crosswise and in turn, lightly tighten the flange bolts and check, by
carefully opening and closing the unit, that the butterfly valve does not
touch the inner wall of the pipeline.
6. Working crosswise and in turn, tighten the flange bolts to the specified
torque.
7. The butterfly valve is now ready for operation

5. DISMOUNTING OF BUTTERFLY VALVE
1. Observe the precautions and safety regulations.
2. The disc must be shut before the unit is removed from the pipeline.
3. Please remember that the interior of the unit may not be completely
empty.
4. Use appropriate lifting gear to secure the unit and detach it from the
pipeline.
5. Work crosswise when loosening the flange bolts.
6. Ensure that the flange mating surfaces are not scratched when
dismantling the unit.

6. MAINTENANCE INSTRUCTIONS
for HP-series EBRO high performance butterfly valves DN50-600
General information:
Lubrication and routine maintenance of the butterfly valve are not necessary,
as the bearing is self-lubricating and the shaft seal is self-adjusting
6.1
Replacing the PTFE (Teflon) shaft seal (item 16)
1. Remove the drive unit or hand lever.

2. Detach the two hexagon nuts (item 20).
3. Remove the spring washers (item 25) and stuffing box gland (item 7).
4. Remove the thrust collar (item 8) and the packing rings (item 16) from the
shaft seal by using an appropriate tool. Attention: be careful not
damaging the surfaces of the stem and bore.
5. Note the installation order and location of the packing rings.
6. Clean out the location seat of the shaft seal. Do not damage the mating
surfaces of either the body or the shaft.
7. Push the new packing rings onto the shaft one by one in reverse order and
press them into the relief of the body.
When installing be careful not to damage the sealing lips of the packing
rings.
8. Place the thrust collar (item 8), spring washers (item 25) and stuffing box
gland (item 7) back on the headless screws (item 19).
9. Working gradually and in turn, tighten the hexagon nuts (item 20) until the
spring washer assemblies are secured.
Now loosen the hexagon nuts by 1-2 turns and check that the stuffing
box gland is parallel to the head flange of the unit.

6.2 Replacing the graphite shaft seal (with metal seat item 16)
1. Remove the actuator or hand lever.
2. Detach the two hexagon nuts (item 20).
3. Remove the spring washers (item 25) and stuffing box gland (item 7).
4. Remove the thrust collar (item 8) and the packing rings (item 16) from the
shaft seal by using an appropriate tool. Attention: be careful not
damaging the surfaces of the stem and bore.
5. Clean the location seat of the shaft seal. Do not damage the mating
surfaces of either the body or the shaft.
6. Place the two replacement packing rings on the shaft and press them into
the relief in the body. Use the thrust collar (item 8), stuffing box gland (item
7) and hexagon nuts (item 20) to press the two newly fitted packing rings
into the body.
7. Repeat this procedure with the remaining packing rings, locating and
pressing them in one by one.
8. Now place the spring washers (item 25) onto the headless screws and,
working gradually and in turn, tighten the hexagon nuts (item 20) until the
spring washer assemblies are secured.
9. Now loosen the hexagon nuts by one turn and check that the stuffing box
gland is parallel to the head flange of the butterfly valve.

6.3 Replacing the PTFE (Teflon) sealing ring (item 5)
1. Remove the valve from the pipeline and secure it in a bench vice or similar
appliance.
2. Open the butterfly valve.
3. Remove the Allen screws (item 17), locking ring (item 3) and sealing ring
(item 5).
4. Polish the mating surface of the butterfly valve (item 2) with a linen cloth.
This helps smooth out small scratches or any other minor damage on the
mating surface.
5. Clean the butterfly valve unit.
6. Grease the sealing ring with a medium-grade lubricant, if permitted.
7. Place the new sealing ring (item 5) in the groove of the body.
8. Attach the locking ring (item 3) and, working crosswise, lightly tighten the
Allen screws (item 17).
9. Close the butterfly valve.
10. Working crosswise, tighten the Allen screws (item 17) to the specified torque.
Torque settings for screws
M5 = 4Nm (DN 50/65, DN 80, DN 100)
M6 = 6Nm (DN 125, DN 150, DN 200, DN 250)
M8 = 14Nm (DN 300, DN 350, DN 400, DN 450)
M10 = 30Nm (DN 500, DN 550)
M12 = 60Nm (DN 600)

6.4 Replacement of the metal sealing ring (item 5)
1. Remove the butterfly valve from the pipeline and secure it in a bench vice
or similar appliance.
2. Open the butterfly valve.
3. Remove the Allen screws (item 17), locking ring (item 3), the sealing ring
(item 5) and the graphite seals (item 24).
mating surface.
5. Clean the butterfly valve.
Any remains of graphite seals (item 24) can be removed from the body
and locking ring using an appropriate solvent.
Do not use any sharp object to remove remains of seals, as this may
damage the mating surfaces.
6. Shut the unit and lay it flat, with the disc facing upwards.
7. Place a graphite seal (item 24) in the body.
Caution!
Handle the graphite seals up to DN 300 with great care. Broken or
damaged seals can cause leakage.
8. Place the metal sealing ring (item 5) on the graphite seal in the body.
Nominal diameters exceeding DN 300: self-adhesive graphite tape is
sticked on the bottom flange surface of the metal seat.
9. Place the second graphite seal (item 24) in the groove of the locking ring
(item 3).
A medium-grade lubricating grease can be used for holding the graphite
seal in position. Nominal diameters exceeding DN 300: self-adhesive
graphite tape is sticked on the clamping ring.
10. Install the locking ring (item 3) in the body, together with the attached
graphite seal.
11. Working gradually and crosswise, tighten the Allen screws (item 17) to the
specified torque.
Torque settings for screws M5 = 5Nm (DN 50/65, DN 80, DN 100)
M6 = 7Nm (DN 150, DN 200, DN 250)
M8 = 17Nm (DN 300)

7. DISMANTLING OF BUTTERFLY VALVE
1. Loosen the hexagon nuts (item 20) on the stuffing box gland and remove
the spring washers (item 25), the stuffing box gland (item 7) and the thrust
collar (item 8).
2. Following the same procedure as for the ring replacement, remove the
locking ring (item 3) and the sealing ring (item 5).
3. Loosen the plug (item 13) and remove the plug seal (item 14).
4. Grind away the weld seam of the key pins (item 12) and push the key pins
out in the opposite direction to that indicated by the arrow.
5.
Remove the shaft (item 4) by lifting it out of the body.

Caution! When the shaft (item 4) is pulled, the disc (item 2) will open.
Avoid damage to the mating surfaces, by propping up the disc to prevent
it from dropping out of the body.
6. 23) and Remove the shaft seal (item 16) the support plate (item 10) the
spacer sleeve (item the shaft bearing (item 6).

8. REFITTING OF DISMANTLED BUTTERFLY VALVE
1. Clean all components and check for damage.
Take special care to examine the shaft seal mating surfaces on the body,
the
shaft itself and the mating surface of the disc.
2. Place the butterfly valve on a workbench with the locking ring side facing
downwards.
mating surface.
4. Fit the plug (item 13) and the plug seal (item 14).
5. Push the lower shaft bearing (item 6) into the relief in the body.
6. Fit the spacer sleeve (item 23) and the support plate (item 10) to the
housing.
7. Using a medium-grade lubricant, lightly grease the hole in the butterfly
valve (item 2) and the shaft (item 4).
8. Place the disc (item 2) in the body. Ensure that the word TOP is facing
the head flange of the unit.
9. Insert the bearing rings (item 9) between the body and the disc (item 2).
10. Run the shaft (item 4) into the body from above. Ensure at this point that
the disc (item 2) is raised slightly.
11. Following the same procedure as for shaft seal replacement, fit the shaft
seal (item 16), the thrust collar (item 8), the stuffing box gland (item 7), the
spring washers (item 25) and the hexagon nuts (item 20).
However do not tighten the hexagon nuts (item 20) at this stage.
12. Using a drift, tap the key pins (item 12) securely into place in the direction
of the arrow.
The key pins (item 12) must be tapped in equally, so that the ends of the
pins all stand proud of the butterfly valve by the same amount.
13. Weld the tapered ends of the key pins (item 12) with the disc. Clean the
welds with a wire brush.
14. Fit the new sealing ring (item 5), as described in the section on sealing ring
replacement.
15. Tighten the hexagon nuts (item 20) on the stuffing box gland (item 7), as
described in the section on replacing the shaft seal.

9.1 Parts list HP111
PTFE sealed
20
28
29
25
16
10
31
30
7
19
2
5
23
27 26
17
14
12
9
13
27 26
Item
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
19
20
23
25
26
27
28
29
30
31
designation
body
disc
clamp ring
shaft
seat
shaft bearing
gland flange
thrust collar
bearing ring
supporting ring
taper pin
plug/cover*
seal
cover screws*
shaft seal
hexagon socket screw
stud bolt
hexagon nut
top distance sleeve
Belleville spring washer
centering piece
countersunk screw
bracket
hexagon screw
hexagon nut
plain washer
* cover of diameters exceeding DN350
type: carbon steel

GS-C25N DIN17245 3.1B
1.4408 EN10213-4 3.1B
St 37 galvanized
1.4418 SEW 400 3.1B
R-PTFE
316SS/ PTFE
St 37 galvanized
1.4301
1.4571 cr. plated
1.4571
1.4418 SEW 400 3.1B
1.0718 ni. plated/St37 galvanized*
PTFE
A2-70
PTFE
A4-70
A2-70
A2-70
PTFE
CrV4
1.4401/1.4571/St37 galvanized
A2
St37 galvanized
St galvanized
St galvanized
St galvanized
6
14
13
15
cover of diameters
exceeding DN
350
type: stainless steel

1.4408 EN 10213-4 3.1B
1.4408 EN 10213-4 3.1B
1.4408
1.4418 SEW 400 3.1B
R-PTFE
316SS/ PTFE
1.4301
1.4301
1.4571 cr. plated
1.4571
1.4418 SEW 400 3.1B
A2-50/1.4401*
PTFE
A2-70
PTFE
A4-70
A2-70
A2-70
PTFE
1.4310
1.4401/1.4571
A2
St37 galvanized
St galvanized
St galvanized
St galvanized

metal sealed
8
20
28
29
25
16
10
19
24
31
30
24
23
27 26
3
17
14
12
9
13
27 26
Item
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
19
20
23
24
25
26
27
28
29
30
31
designation
15
cover of diameters
exceeding DN350

body
1.4408 EN 10213-4 3.1B
1.4408 ni. plated EN 10213-4 3.1B 1.4408 EN 10213-4 3.1B
disc
clamp ring
St 37 galvanized
1.4401
shaft
1.4418 SEW 400 3.1B
1.4418 SEW 400 3.1B
seat
Inconel
Inconel
shaft bearing
1.4571 nitride QPQ
1.4571 nitride QPQ
gland flange
St 37 galvanized
1.4301
thrust collar
1.4301
1.4301
bearing ring
1.4571 cr. plated
1.4571 cr. plated
supporting ring
1.4571
1.4571
taper pin
1.4418 SEW 400 3.1B
1.4418 SEW 400 3.1B
1.0718 ni. plated/St37 galvanized* A2-50/1.4401*
plug/cover*
seal
graphite
graphite
cover screws*
A2-70
A2-70
shaft seal
graphite
graphite
hexagon socket screw A4-70
A4-70
stud bolt
A2-70
A2-70
hexagon nut
A2-70
A2-70
top distace sleeve
1.4571
1.4571
graphite seal
graphite
graphite
Belleville spring washer CrV4
1.4310
centering piece
1.4401/1.4571/St37 galvanized 1.4401/1.4571
countersunk screw
A2
A2
bracket
St37 galvanized
St37 galvanized
hexagon screw
St galvanized
St galvanized
hexagon nut
St galvanized
St galvanized
plain washer
St galvanized
St galvanized
type: carbon steel

GS-C25N DIN17245 3.1B
6
14
13

PTFE sealed
20
28
29
25
16
10
31
30
7
19
2
5
23
1
6
3
17
14
12
9
13
6
14
13
Item
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
19
20
23
25
28
29
30
31
designation
body
disc
clamp ring
shaft
seat
shaft bearing
gland flange
thrust collar
bearing ring
supporting ring
taper pin
plug/cover*
seal
cover screws*
shaft seal
hexagon socket
stud bolt
hexagon nut
top distance sleeve
bracket
hexagon screw
hexagon nut
plain washer
type: carbon steel

GS-C25N DIN17245 3.1B
1.4408 EN10213-4 3.1B
St 37 galvanized
1.4418 SEW 400 3.1B
R-PTFE
316SS/ PTFE
St 37 galvanized
1.4301
1.4571 cr. plated
1.4571
1.4418 SEW 400 3.1B
1.0718 ni. plated/St37 galvanized *
PTFE
A2-70
PTFE
A4-70
A2-70
A2-70
PTFE
CrV4
St 37 galvanized
St galvanized
St galvanized
St galvanized
15
cover of diameters
exceeding DN350
type: stailess steel

1.4408 EN 10213-4 3.1B
1.4408 EN 10213-4 3.1B
1.4408
1.4418 SEW 400 3.1B
R-PTFE
316SS/ PTFE
1.4301
1.4301
1.4571 cr. plated
1.4571
1.4418 SEW 400 3.1B
A2-50/1.4401*
PTFE
A2-70
PTFE
A4-70
A2-70
A2-70
PTFE
1.4310
St 37 galvanized
St galvanized
St galvanized
St galvanized

metal sealed
20
28
29
25
16
10
19
24
31
30
24
23
1
6
3
17
14
12
9
13
6
14
13
15
cover of diameters
exceeding DN350
Item
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
19
20
23
24
25
28
29
30
31
designation
body
disc
clamp ring
shaft
seat
shaft bearing
gland flange
thrust collar
bearing ring
supporting ring
taper pin
plug/cover*
seal
cover screws*
shaft seal
hexagon socket screw
stud bolt
hexagon screw
top distance sleeve
graphite seal
bracket
hexagon screw
hexagon nut
plain washer
type: carbon steel

GS-C25N DIN17245 3.1B

1.4408 EN 10213-4 3.1B
1.4408 ni. plated EN 10213-4 3.1B 1.4408 EN 10213-4 3.1B
St 37 galvanized
1.4401
1.4418 SEW 400 3.1B
1.4418 SEW 400 3.1B
Inconel
Inconel
1.4571 nitride QPQ
1.4571 nitride QPQ
St 37 galvanized
1.4301
1.4301
1.4301
1.4571 cr. plated
1.4571 cr. plated
1.4571
1.4571
1.4418 SEW 400 3.1B
1.4418 SEW 400 3.1B
1.0718 ni. plated/St37 galvanized* A2-50/1.4401*
graphite
graphite
A2-70
A2-70
graphite
graphite
A4-70
A4-70
A2-70
A2-70
A2-70
A2-70
1.4571
1.4571
graphite
graphite
CrV4
1.4310
St 37 galvanized
St 37 galvanized
St galvanized
St galvanized
St galvanized
St galvanized
St galvanized
St galvanized
Forms
Form Operating Log book

for Hot water boiler
L004
Version 3 (08/05)
Calender year
Boiler:
Month
Type
Serial number
9
Deadline
Test criteria marked with:
not in order
not applicable, not provided
1 week
mg
l
S .
cm
Signature of person responsible
electr. conductivity (original)

at 25C
Appearance colourless, clear, free
from undissolved substances or
cloudy
Phosphate PO4
Na2SO3 or ...
or
Oxygen binder
mg
l
Burner start-up impulse no.
mg
l
Burner operating hours
Oxygen O2
Earth alkalis (total hardness dH)
KS8,2 (p value)
mmol mmol
l
l
Total operating hours
mmol
l
Return flow temperature
mg
l
Meter reading
Supply flow temperature
pH value at 25C
For comments, see page 4
Earth alkalis (total hardness dH)
For comments, see page 4
Oxygen O2
Circulating water
pH value at 25C
Filling and
make-up water
Quantity of water added later

Week
in order
Year of manufacturer
1 27
2 28
3 29
4 30
5 31
6 32
7 33
8 34
9 35
10 36
11 37
12 38
13 39
14 40
15 41
16 42
17 43
18 44
19 45
20 46
21 47
22 48
23 49
24 50
25 51
26 52
Page 1 of 4
Safety valves
Filling test device
Drainage and blowdown device
Valves
Level limiter
Flow monitor
Pressure display or temperature display
Temperature regulator
Pressure limiter or temperature limiter
Inspection openings
Top-up and circulation devices
Equipment for monitoring the boiler water for foreign bodies
Flue gas valve limit switch
Control elements for air and fuel (mixture)
Combustion air blower, ignition and/or cooling air blower
Air pressure quantity display and air pressure monitor
Fuel shutoff devices
Fuel safety shutoff device before burner
Leak-tightness monitoring device with gas valves
Ventilation of furnaces and flue gas lines
Ignition
Flame monitoring
Day
Deadline

Version 3 (08/05)
Boiler:
Key to symbols:
L004
Calender year
Type
Serial number
Month

9
in order
8
not in order
For the tests, the specifications in Operating Instructions B007 Checklist for hot water boilers must be followed.
Observe (B)
Observe abnormal noises, odours or other notable occurrences
Function test (F)

Test the functional behaviour of equipment parts, incl. observation
Boiler
Burner unit
3 days
Page 2 of 4
11
Valves
Pipes
Level limiter
Flow monitor
Pressure display or temperature display
Pressure limiter or temperature limiter
Top-up and circulation devices
Equipment for monitoring the boiler water for foreign bodies
Control elements for air and fuel (mixture)
Fuel shutoff devices
Fuel safety shutoff device before burner
Leak-tightness monitoring device with gas valves
Flame monitoring
Emergency switch
Safety valves
Temperature regulator
Inspection openings
Assessment of furnaces and flue gas lines
Filling test device
Buffer battery for automation device C7-633
Air pressure quantity display and air pressure monitor
month
Deadline

Version 3 (08/05)
Boiler:
Key to symbols:
L004
Calender year
Month
Type
Serial number

9
in order
8
not in order
1 month
Date:
Date:
For the tests, the specifications in Operating Instructions B007 Checklist for hot water boilers must be followed.
Observe (B)
Observe abnormal noises, odours or other notable occurrences
Function test (F)

Test the functional behaviour of equipment parts, incl. observation
Boiler
Burner unit
3 months
6 months
Date:
12 months
Date:
Date:
Date:
10
12
Date:
Page 3 of 4

L004
Version 3 (08/05)
Particular incidents
Other comments
Technical measures required
Place, date
Signature
For notes on the scope and dates of tests and regulations for testing, please see the following Operating Instructions:
K002 Full-stroke safety valves
I001 Level limiter electrode
I003 Pressure transducer
Comments
Water samples should only be taken from the system during normal operation, i.e. not in the cold state or during start-up.
The analysis must be carried out as soon as the sample has been removed.
For the water tests, please follow the instructions in Operating Instructions B004 Guideline on Water Characteristics for Hot
Water Boilers.
Filling and make-up water
Testing according to
Regulations issued by the supplier of the water treatment plant (operating sheets)
"Filling and make-up water" column basically, the following characteristics should be determined
a
b
c
d
Circulating water
Testing according to
"Circulating water" column basically, the following characteristics should be determined

e or f
g
h or i
k
l
The oxygen binder used should be indicated.
Page 4 of 4
After Sales Services

Enquiry/Order
L006
Version 3 (04/07)
Your address:
Order
...........................................................................
Enquiry
...........................................................................
To LOOS INTERNATIONAL
...........................................................................
After Sales Services
...........................................................................
Name of customer: ...........................................
Fax-Nr. ++49 9831 56 92 335
Customer no: ....................................................
e-mail: ersatzteile@loos.de
Issued by: .........................................................
Loos Austria GmbH (for installation country Austria)

Fax-Nr. ++43 6462 2527 66 320
e-mail: ersatzteile@loos.at
Enquiries on spare parts or orders for spare parts are very easy for you using this form. Complete data, check if this is an
enquiry or an order, send complete. We will immediately tend to your wishes. Please observe that we only execute orders
subject to the applicable sales and delivery conditions of Loos International. If you would like to replace parts of your boiler,
then we will quickly supply the required parts without any complications.
We require the following data about your boiler so that we will be able to process your enquiry respectively order even faster.
Order no.: .....................................
(in the file operating instructions boiler)
Manufacturer no.: .....................................

(see rating plate)
and boiler model: .................................

(see rating plate)
Desired parts
Ident no.
Name/Description
Please deliver the parts to the following address:

(only complete if the parts are to be sent to an address different from the one above)
.....................................................................................................................................
.....................................................................................................................................
.....................................................................................................................................
.....................................................................................................................................
Desired date:
.......................................
Place/Date:.........................................................................
Signature:..................................................................
Quantity
Test Certificate
Regular Inspections External Inspections

L007
Version 3 (08/09)
Date of external inspection

X
Boiler:
Monitoring organisation
Type
Factory number
Heat output / kW
Steam output in kg/h
Flue gas heat exchanger:
Type
Factory number
Heat output in kW
Superheater:
Type
Factory number
max. perm. temp. in C
Burner:
Make
Type
Oil / gas / dual
Control cabinet:
Make
First start-up of boiler system
max. perm. pressure in bar
Year built
See the following Operating Instructions for notes on the scope of inspections, inspection intervals and requirements for carrying out inspections
B006 Regular inspections for shell boilers (> 1.0 bar / > 120 C)
B008 Regular inspections for quick steam generators

B009 Regular inspections for shell boilers (<= 1.0 bar / <= 120 C)
B011 Regular inspections for shell boilers (<= 190 C; Boilers with simple inspection facilities)
B012 Regular inspections for shell boilers (<= 16 bar; Boilers with simple inspection facilities)
Explanation of abbreviations:
VI
Visual inspection
FT Function test
O Other tests
B
Boiler, burner, control cabinet and associated valves and pipes
S
Superheater and associated valves and pipes
F
Flue gas heat exchanger and associated valves and pipes
Inspection criteria market with:
in order
Point to be tested (if there are

several of one component, they
must all be tested)
Note
Tests
General
General condition
Condensation,
discolouring, vibrations,
etc.
VI
Visible ducts on the

flue gas side
e.g. furnace, inspection

openings on flue gas side
VI
Brick lining
as far as visible
VI
Heat insulation
Inspection openings
Burner
not relevant, because not provided
Comments (additional comments may also be added at the end

of the table)
VI
Burner
Components
with a
safety
function
not in order
VI
VI
Fuel pipes
Oil, gas, plus valves up to

manual shut-off valve
VI, O
Air and flue gas

pipe
incl. combustion air,

compressed air
VI
Steam and water

pipes
Steam, feed water,

drainage, emptying and
blow-down pipes, etc.
VI
Level limiting device
FT
Pressure limiter
Ft
Temperature limiter
FT
Pressure safeguard
valve
triggered in good time,

function, secure against
adjustment
FT, O
Valves
display? function?
VI, FT
Non-return valve
impermissible pressures?
function?
FT, O
Oil preheater
limiter
VI, FT
Fuel pipes
plus leak tightness test

(e.g. spray to find leaks)
VI, O
Page 1 of 2
Test Certificate
Regular Inspections External Inspections

L007
Version 3 (08/09)
Note
Tests
Safety shut-off
devices
Function and leaktightness e.g. for solenoid

valves, shut-off valves,
gas regulating module
VI, O
Burner equipment
if provided: adjustment
devices, air/fuel,
min./max. pressure
monitor, oil/gas, air
pressure monitor
VI, FT
Point to be tested (if there are

several of one component, they
must all be tested)
Safety
power
circuit
Furnace brick lining
VI
Flame appearance
Flame monitor
FT
Safety,
maintenance, rinse
and ignition time
FT
Fuses
correct?
VI
Wiring
correct?
VI
Characteristics
in order?
VI
Operating
conditions
as designed?
Emergency stop
function
FT
Running
Check that
operating log is
complete & correct
operating records: daily,

weekly, monthly, etc.
VI, O
Operating
Operating
instructions
available?
VI, O
Operating and
maintenance staff
familiar with operation
Comments (additional comments may also be added at the end

of the table)
Names of operating and maintenance staff:
Extraordinary external inspections
Other comments
Place, date
Signature
Next inspections:
External inspection
Internal inspection
Water pressure test
Extraordinary inspection
Page 2 of 2
Test Certificate
Regular Inspections Internal Inspections

L008
Version 3 (07/09)
Date of internal inspection

X
Boiler:
Type
max. perm. pressure / bar
Factory number
Year built
Heat output / kW
Type
Factory number
Heat output in kW
Superheater
Type
Factory number
Burner:
Make
Type
Oil / gas / dual
Control cabinet:
Make
Part internal inspection (boiler cannot be examined fully)
Note: After the internal inspection, an external inspection must be carried out
B006 Regular inspections for shell boilers (>1.0 bar / > 120 C)
Explanation of abbreviations:
B Boiler
S Superheater
F Flue gas heat exchanger
Inspection criteria market with:
Point to be tested
in order
Note
Boiler shell
Discolouring? Deposits?
Reversing chamber
casing, cover, floor
not in order
Comments (additional comments may also be added at

the bottom)
Pipe plates
Visual
inspection of
walls
Boiler ends
Smoke tubes
esp. at entr. to 2nd tubing,

deposits?
Flame tube
deposits?
Flanges
cracks?
Flame tube/ends
Flame tube/reversing
chamber
Visual
inspections at
welded
joints
Shell / ends
Smoke tube welded inserts
esp. cross-pieces
Connection pieces
esp. water leaking in
Anchors
e.g. welding of corner anchors
Reversing chamber
Inspection openings
Flame tube
Visual
inspection on
flue gas
side
Reversing chamber(s)
Pipe bundles
esp. corrosion damage
Inspection openings
flue gas side
Page 1 of 2
Test Certificate
Regular Inspections Internal Inspections

L008
Version 3 (07/09)
Extraordinary internal inspections
Other comments
Place, date
Signature
Next inspections:
External inspection
Internal inspection
Water pressure test
Page 2 of 2
Test Certificate
Regular Inspections Water Pressure Test

L009
Version 3 (08/09)
Date of water pressure test

X
Boiler:
Type
Factory number
Heat output in kW
Type
Factory number
Heat output in kW
Superheater:
Type
Factory number
max. perm. pressure in bar
Year built
Test pressure in bar
B006 Regular inspections for shell boilers (> 1.0 bar / > 120 C)
B008 Regular inspections for quick steam generators
Inspection criteria market w:
Test plan
in order
not in order
Note
Comments (additional comments may also

be added below)
Calibrated manometer provided?

Boiler cooled and system prepared?
Note the safety requirements
Boiler filled with water?
Warning: danger of thermal shock
Start 1st pressure application
Time: _________________
Increase pressure to 75% of test pressure
max. 10 bar / min
max. 2 bar / min
Monitoring during holding time
Holding time approx. half an hour

Check all accessible weld seams for leaks, insulation
for wetness and manometer for fall in pressure.
Watch out for cracks and deformation.
Fall in pressure
as rise in pressure
Start 2nd pressure application
Time: _________________
max. 10 bar/min
max. 2 bar/min
Monitoring during holding time
Holding time approx. half an hour

Check all accessible weld seams for leaks, insulation
for wetness and manometer for fall in pressure.
Watch out for cracks and deformation.
Fall in pressure
as rise in pressure
End of water pressure test
Time: _________________
Note: After the water pressure test, an internal (if possible as far as boiler is concerned) and an external inspection should generally be carried out.
Extraordinary water pressure test
Other comments
Page 1 of 2
Test Certificate
Regular Inspections Water Pressure Test

L009
Version 3 (08/09)
Place, date
Next inspections:
External inspection
Signature
Internal inspection
Water pressure test
Page 2 of 2
Return Note
Please observe the notes on the following page!
L014
Version 2 (10/09)
Consignee
LOOS INTERNATIONAL
Ersatzteillager
Industriestrae 1
91710 Gunzenhausen
Germany
Consignor
Company
Street:
Postcode / place:
Country:
Customer No.:
Date:
Contact person:
Phone:
eMail:
Delivery Note No.
Material No.
Invoice No.
Quantity Unit
Order No.
Description
Serial No.
Condition*
Reason for
return*
Detailed fault description:
* Please enter the condition and the reason for return in the corresponding column:
Condition
001
003
New part OK
Defective new part
002
004
Used part OK
Defective used part
20
21
23
24
30
31
Material / processing fault

Expiration date expired
Transport damage
Not required any more
Warranty
Sample
Possible reasons for return:

10
12
13
14
15
16
Wrong delivery of an item

Wrong quantity delivered
Double delivery
Delay in delivery
Incomplete item
Incorrect order
32
33
34
35
36
Repair
Software update
For inspection
Rental device
Other reasons
Please send us a separate order if you need replacement for returned parts.
Date
Signature
Internal notes by LOOS:

Received:
ASP:
Person in charge:
ZRET:
Location:
Return Note
Important note on the returns process!
L014
Version 2 (10/09)
Dear Customer,
Thank you very much for your order. We want you as our customer to be completely satisfied with our products.
If you have any questions about the returns process, please contact our spare parts service as a first step, as many
problems can already be solved beforehand.
If, in spite of this, it should be necessary to return a product, we request you to proceed as follows:
1. Please fill in the return note completely and attach a return note and a copy of the delivery note or the invoice
to each return consignment in order to ensure fast and trouble-free processing. A return note template is also
provided in the internet at www.loos.de/Service/Returns.
You can help us to process your return more quickly by attaching a detailed fault description of defective
parts or incorrect or incomplete deliveries sent to us for service under guarantee or repair. In case of transport
damage we require a written confirmation of the carrier.
Otherwise we cannot process your claim and will return the parts to you after 2 weeks carriage freight collect.
2. Please send the goods to the address indicated on the return note in a sufficiently post paid and carefully
packaged way.
3. For returns outside the EU it is necessary to attach an invoice to the consignment on principle. For defective
or damaged parts please issue an invoice with a lower invoice value for customs purposes and explicitly
declare them as defective parts.
The prerequisite for the return of parts outside the warranty is a repair order. Please contact our spare parts service
for a repair order in advance.
When materials are returned for crediting we generally deduct 20% (however at least 25 ) inspection and return
costs. Wearing parts are generally non-returnable.
Kind regards,
LOOS INTERNATIONAL
Spare Parts Service
Nrnberger Strae 73
91710 Gunzenhausen
Germany
Phone: +49 9831 56368
PCFax +49 9831 5692368
eMail: retoure@loos.de
For
Formula 1
Boiler Service
Technical data
Page 1
Technical Data
Position
Description
Attribute
Unit
Value
General Data
Country of destination
Location
Assembly and operating conditions
Erection altitude max. about sea level
Ambient temperature min.
Ambient temperature max.
Voltage
Voltage fluctuations max. +/Neutral conductor
Earth connection
Frequency
Max. frequency fluctuations (+/-)
Direct switching up to
Water quality
Loos Deutschland GmbH, www.loos.de

Sitz: Nrnberger Str. 73, D-91710 Gunzenhausen
Geschftsfhrung: Joachim Lenz, Martina Loos, Rudolf Hofmann
Registergericht: Amtsgericht Ansbach HRB 87

USt-IdNr.: DE 131 937 341
Commerzbank AG, Nrnberg

Hypo Vereinsbank GmbH, Gunzenhausen
Vereinigte Sparkassen, Gunzenhausen
Kto-Nr.: 5215363
Kto-Nr.: 2906880
Kto-Nr.: 102525
BLZ: 760 400 61

BLZ: 765 200 71
BLZ: 765 515 40
m
C
C
V
%
Hz
%
kW
IBAN: DE82 7604 0061 0521 5363 00

IBAN: DE70 7652 0071 0002 9068 80
IBAN: DE17 7655 1540 0000 1025 25
Romania
indoors
Free of frost, dust as well
as dripping water
300
20
40
400
5
yes
yes
50
1
5,5
acc. to Operating Manual
"Directive water condition"
B002 resp. B004
SWIFT-BIC.: COBADEFF760
SWIFT-BIC.: HYVEDEMM406
SWIFT-BIC.: BYLADEM1GUN
Page 2
Position
Description
Attribute
Unit
Value
02
Hot water boiler plant
02.01
Power output system boundary

kW
70000
Trip temperature for the safety limiter
C
130
Trip pressure safety valve
bar
12,0
Supply flow temperature
C
120
Return flow temperature
C
80
Max. alowable geodetic height difference
m
82,15
Fuel
Gas / Natural Gas H
All details ref. to the O2-contents in the dry smoke %
2,1
gas of
Fuel standard
DVGW G260
Net calorific value (rated to 0 C / 1013 mbar) (gas) kWh/nm3
9,85
Gas flow pressure
mbar
500
LOOS Three-Pass Flame Tube Smoke Tube Boiler UNIMAT, Type UT-HZ
02.01.01
Boiler Type (UT-HZ)

Design pressure
Nominal capacity
Operation side
Test pressure
Category (DGRL)
Max. adm. temperature difference
Min. permitted return flow temperature
Boiler and equipment
Water-side resistance boiler
Nominal size Supply flow socket
Nominal size Return flow socket
Nominal diameter flue gas connection (DIN24151,
DIN24154)
Number of flue gas connection sockets
Efficiency gas (acc. to EN 12953 part 11 - indirect
method)
Total burner capacity (gas)
Norm volume flow fuel (gas)
Norm volume flow moist smoke gas (gas)


USt-IdNr.: DE 131 937 341

Kto-Nr.: 5215363
Kto-Nr.: 2906880
Kto-Nr.: 102525
BLZ: 760 400 61

BLZ: 765 200 71
BLZ: 765 515 40
bar
bar
kW
bar
K
C
36000
13,0
11,5
35000
right-hand side
24,0
IV
40,0
60,0
mbar
DN
DN
DN
83,72
350
350
1250
1,0
93,3
%
kW
m/h
m/h
IBAN: DE82 7604 0061 0521 5363 00

IBAN: DE70 7652 0071 0002 9068 80
IBAN: DE17 7655 1540 0000 1025 25
37500
3807
43161
Page 3
Position
Description
Attribute
Unit
Value
kg/h
%
53588
6,5
C
m/h
m/h
mbar
173
784,9
232,3
23,7
mbar
0,0
mbar
-1,0
db(A)
85,0
02.01.02
Mass flow moist smoke gas (gas)

Flue gas loss approx. (acc. to prEN 12953 Part 11)
(gas)
Flue gas temperature approx. (gas)
Water flow
Min. water flow
Resistance on heating gas side - boiler without ECO
(fuel gas)
Max. admissible flue gas pressure of flue gas combination at site
Min. admissible flue gas pressure on flue gas combination at site
Total sound pressure level caused by flue gas noises
from the boiler system at the chimney opening (see
TI032)
Transportation weight boiler body approx. +/- 4%
Total weight boiler body (full) approx. +/- 2%
Insulation thickness min.
Boiler control panel
02.01.03
Protection type
Extra space in the boiler control panel
Installed load
Display size Touch Panel
Cable harness feeder at the boiler (oclock)
Cable harness length
Firing equipment
kg
kg
mm


USt-IdNr.: DE 131 937 341

Kto-Nr.: 5215363
Kto-Nr.: 2906880
Kto-Nr.: 102525
BLZ: 760 400 61

BLZ: 765 200 71
BLZ: 765 515 40
IP54
20
167,18
10 inch
12
10,0
%
kW
Emission evaluation according to

emissions
Type of control (gas)

Temperature of aspirated air
Rated Capacity engine(s)
Weight burner
Width control panel for external frequency converter
75624
146094
100
C
kW
kg
mm
IBAN: DE82 7604 0061 0521 5363 00

IBAN: DE70 7652 0071 0002 9068 80
IBAN: DE17 7655 1540 0000 1025 25
EN 267/676
(Basis for NOx: NO2 related to 3% O2 in dry flue
gas)
Continuous modulating
25,0
0,0
435
800
Page 4
Position
Description
Attribute
Unit
Value
height control panel for external frequency converter

depth control panel for external frequency converter
Base height control panel for external frequency
converter
Weight fan
Place of installation for fan
mm
2000
mm
mm
500
100
kg
850,0
on top of boiler (fan console)
02.01.04
Gas regulation module GRM

500
02.01.04.01
Gas flow pressure at inlet of gas regulation module mbar

Gas regulation module(s)
2000
02.01.05.01
Max. permissible gas flow pressure of the gas regu- mbar

lation module (safeguarding pressure of gas transfer
station)
Shipment weight GRM
kg
Gas meter
02.01.07
Type gas consumption meter

Return temperature boosting equipment
02.01.08
min. necessary residual feed pressure

min. return flow temperature
Nominal diameter admixing line
Transportation weight Return flow temperature safeguard
Flue gas silencer
6500,0
1900,0
1250
02.02
Built-in length
mm
External diameter
mm
Nominal diameter flue gas connection (DIN24151, DN
DIN24154)
Material specification
Resistance flue gas silencer
mbar
LOOS Three-Pass Flame Tube Smoke Tube Boiler UNIMAT, Type UT-HZ
Boiler Type (UT-HZ)
Design pressure
Nominal capacity
36000
13,0
10,5
35000
QA 1000
mbar
C
DN
kg
50,0
45,0
250
700,0
bar
bar
kW


USt-IdNr.: DE 131 937 341

Kto-Nr.: 5215363
Kto-Nr.: 2906880
Kto-Nr.: 102525
BLZ: 760 400 61

BLZ: 765 200 71
BLZ: 765 515 40
307,25
IBAN: DE82 7604 0061 0521 5363 00

IBAN: DE70 7652 0071 0002 9068 80
IBAN: DE17 7655 1540 0000 1025 25
Steel
0,24
Page 5
Position
Description
Attribute
Unit
02.02.01
Operation side
Test pressure
Category (DGRL)
Max. adm. temperature difference
Min. permitted return flow temperature
Boiler and equipment
02.02.02
see item 02.01.01

Boiler control panel
02.02.03
see item 02.01.02

Firing equipment
02.02.04
see item 02.01.03

Gas regulation module GRM
02.02.04.01
see item 02.01.04

Gas regulation module(s)
02.02.05.01
see item 02.01.04.01

Gas meter
02.02.07
see item 02.01.05.01

Return temperature boosting equipment
02.02.08
see item 02.01.07

Flue gas silencer
bar
K
C
Value
right-hand side
24,0
IV
40,0
60,0
see item 02.01.08


USt-IdNr.: DE 131 937 341

Kto-Nr.: 5215363
Kto-Nr.: 2906880
Kto-Nr.: 102525
BLZ: 760 400 61

BLZ: 765 200 71
BLZ: 765 515 40
IBAN: DE82 7604 0061 0521 5363 00

IBAN: DE70 7652 0071 0002 9068 80
IBAN: DE17 7655 1540 0000 1025 25
Main dimensions
UNIMAT Hot Water Boilers UT-HZ

in three-pass flame-tube smoke-tube technology
DA151
Project number: 119398/32.474

order number: 21068100-474
51.002
51.004
A01.000
D03.000
D03.001
D03.002
D04.007
D05.001
D05.002
D05.004
D05.005
D06.000
Printing date: 18.06.2009
Instrument box option

terminal box
Burner
Flue gas connection socket
Flue gas collection chamber
Flue gas chamber
Inspection opening water side
Inspection opening flue gas side
Sight hole
Base frame
Warning: dangerous
voltage
electrical
D06.002
D07.000
D08.000
D10.000
D11.000
D12.001
D12.503
D14.001
D14.002
D14.005
Lifting lug
Operating platform option
Pressure safeguard valve 1
Pressure safeguard valve 2
Supply flow
Return flow
Drain shut-off valve
Connection for drainage flue gas condensate
Pressure indicator (with test unit)
Pressure limiter
Shut-off valve
Lifting equipment to be fastened

here, only
Page 1 of 2
Warning: hot surface, e. g. uninsulated fitting
Main dimensions

DA151

UNIMAT Hot Water Boilers

Type
Mean working gauge pressure
UT-HZ 36000
Transportation weight
[bar]
[kg]
[kg]
75624
146094
Dimension(s)
L1
L2
1)
Maximum weight
L3
L4
3)
Flue gas connection

B1
1)
H1
H2
1)
L 11
H3
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
12123
10675
8000
1815
4500
6392
5085
1140
4303
Base frame
L 10
2)
L5
L6
L7
L8
L9
B2
Universal columne
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
(IPB-HEB-DIN 1025)
6250
5650
1175
875
300
425
3100
300
Missing dimensions are not contained in scope of delivery.
Dimensioning insertion opening:
References and defaults to Requirements for the boiler installation room see technical information TI024.
Dimensions with 1 % tolerance; transport weight indication with 4 % tolerance and operating weight indication with 2 % tolerance
Positioning height: addition of at least 100 mm to dimension H1 resp. dimension H2
Positioning width: addition of at least 200 mm to dimension B1
(mounted / not mounted fittings)

(mounted / not mounted fittings)
1)
Smallest transport dimensions once fittings, burner and terminal box have been removed (without cable ducting; with cable ducting
2 x + 75 mm).
2)
3)
The boiler operating weight must be absorbed by the foundation in the area of the front and rear supports.
Maximum weight incl. 100 % filled with water
Page 2 of 2
Individual dimensions

DA152

D03.000
D03.001
D05.001
D05.002
D05.004
Flue gas connection socket

Flue gas collection chamber
Inspection opening water side
D08.500
D10.500
D11.500
D12.500
D12.503
Page 1 of 2
Connection for Pressure safeguard valve 1

Connection for Pressure safeguard valve 2
Connection for Supply flow
Connection for Return flow
Connection for drain
Connection for drainage flue gas condensate

DA152

UNIMAT
Dimension(s)
Hot Water Boilers
L1
B1
H1
Type
[mm]
[mm]
[mm]
UT-HZ 36000
10675
4500
4930
Nozzle position
L3
L4
L5
L6
L9
B4
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
6200
3025
2425
725
475
1350
Nozzle position
B5
H2
H4
H6
H7
[mm]
[mm]
[mm]
[mm]
[mm]
350
5010
1420
235
632
Flue gas connection
Base frame
L7
H3
L2
L8
B2
H5
Universal columne
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[IPB-HEB-DIN 1025]
1140
4303
6250
875
3100
335
300
Connection
D03.000
1)
D08.500
2)
D10.500
2)
D11.500
2)
D12.500
2)
D12.503
DN
[mm]
1250
200
350
350
40
3/4
PN
[bar/120C]
0,1
25
25
25
40
0,1
Missing dimensions are not contained in scope of delivery.
Dimensions with 1 % tolerance
1)
Nominal diameter for pipe connection according to DIN 24154 part 4
2)
Nominal diameter for flanges according to DIN 2633 / 2634 / 2635
3)
Pipe thread according to DIN 2999
Page 2 of 2
3)
Piping diagram

DA113

Position
Designation
Position
D08.000
Pressure safeguard valve
D12.002
Quick shut-off blow down valve (manual)
D08.100
D14.001
D10.003
temperature indicator
D14.002
Pressure limiter
D10.004
Temperature limiter
D14.005
Shut-off valve
D10.012
filling test equipment
D14.006
Pressure limiter
D10.013
flow monitor
D14.010
Shut-off valve (test unit)
D10.014
temperature controller
D14.011
Shut-off valve (test unit)
D10.104
Temperature limiter
D14.017
limit switch
D11.003
D15.004
D11.004
temperature monitor
D15.006
Level limiter
D12.001
Drain shut-off valve
D15.013
Page 1 of 2
Designation
Piping diagram

DA113

Position Piping
Position
Piping
08.001
Pressure safeguard blowoff line
10.001
hot water supply flow line
08.002
Pressure safeguard drainage line
11.001
hot water return flow line
08.003
pressure safeguard vapour line
12.001
Drain pipe
08.101
Pressure safeguard blowoff line
12.004
Discharge line flue gas condensate
08.102
Pressure safeguard drainage line
23.001
Flue gas line
08.103
pressure safeguard vapour line
23.002
Flue gas line
The scope of delivery is defined in the order confirmation.
Page 2 of 2
Main and individual dimensions
Gas Regulation Module High-pressure GRMH

DA038

A38.009
expansion fitting
A38.002
pressure regulator valve
A38.007
Pressure indicator
A38.008
Pressure indicator
A38.013
safety shut-off valve
A38.014
A38.005
gas meter
A38.030
A38.003
Filter valve
A38.004
Shut-off valve
Inlet
1)
Outlet
Dimension(s)
L1
B1
H1
H2
1)
H3
[DN]
[DN]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[kg]
125
150
3900
360
735 ... 806
425
405
310 ... 381
307
flange
flange
DIN 2633
DIN 2501
Dimensions with 1 % tolerance; transport weight indication with 4 % tolerance and operating weight indication with 2 % tolerance
Space requirement for spring removal GDR
Main dimensions
Supply Flow Adapter Piece

for UNIMAT Hot Water Boilers, Safeguard temperature 240C,
equipped acc. to EN 12953 - part 6
D15.006
D10.500
D10.004
D10.014
D14.001
~770
700
D14.005
DA137
Edition 5 (03/06)
D14.002
D14.006
D10.012
BAR
D10.500
D10.013
B1
B2
D10.500
D10.004
D10.012
D10.013
D10.014
D14.001
D14.002
D14.005
D14.006
D15.006
Supply Flow
Adapter Piece
type
~510
L1
Connection for supply flow

Temperature limiter (double thermostat)
Filling and test device (blanking plug)
Flow monitor
Temperature controller (only with infinitely variable performance regulation)
Pressure limiter (max.)
Manostat tube shut-off valve DN 20
Pressure limiter (min.)
Level limiter
Nominal
width
Dimensions
Volume
D10.500
L1
B1
B2
[DN]
[mm]
[mm]
[mm]
[l]
(Option)
PN16
PN25
PN40
[kg]
[kg]
[kg]
VL-H
50
50
155
450
405
4,3
33
VL-H
65
65
155
450
405
4,8
34
35
VL-H
80
80
155
450
405
4,8
34
36
VL-H 100
100
165
460
415
6,8
41
45
VL-H 125
125
175
475
430
10,3
47
52
VL-H 150
150
185
490
445
14,3
52
60
VL-H 200
200
200
515
470
23,3
68
78
87
VL-H 250
250
220
540
495
37,3
82
105
123
VL-H 300
300
240
565
520
53,0
100
116
172
VL-H 350
350
250
580
535
62,0
134
163
212
VL-H 400
400
270
610
565
83,0
146
211
273
VL-H 500
500
305
660
615
131,0
215
280
330
Usual assembly at the boiler see data sheet Main dimensions of the boiler
Type of flange connections according to DIN 2633/2634/2635 corresponding to the max. permissible operating gauge pressure of the boiler
Subject to change
Piping diagram
UNIMAT Hot water boiler UT-L, UT-M, UT-H, UT-HZ

Return flow temperature boosting RTA
DA115
Version 4 (03/09)
D10.004
Temperature limiter
D11.012
Shut-off valve (motorized)
D10.014
Temperature limiter
D11.504
Connection for temperature monitor
D10.013
Flow monitor
D10.014
Temperature controller
1
1
D13.003
Shut-off valve
D13.004
Non-return valve
D10.008
Shut-off valve
D13.005
Shut-off valve
D11.003
Temperature switch
D13.006
Booster pump
D11.009
Temperature switch
D13.008
Orifice
Pipings
10.001
Hot water supply flow line
13.001
Admixing line
11.001
Hot water return flow line
13.002
Admixing line
11.002
Safety expansion line
Safety equipment please refer to data sheets DA111 / DA112 / DA113.
Observe Operating Instruction E016.
The scope of delivery is defined in the order confirmation.
Mounting place before admixing line must be taken into account. Devices are part of the safety equipment.
Temperature switch not applicable for speed-controlled booster pump.
if necessary.
Subjecto to change
Main dimension
Flue gas silencer

Reduction of the total sound pressure level at the chimney
opening around 15 dB(A) or 25 dB(A) 1)
DA125
Version 6 (02/08)
Installation in horizontal flue gas line
Installation in vertical flue gas line
Lifting equipment may only be attached at these points
A81.001
A81.002
A81.003
Warning: hot surfaces, e.g. uninsulated fittings
Flue gas silencer

Connecting branch flue gas silencer
Drainage connection socket for flue gas condensate
Flue gas silencer

2)
125
160
200
250
315
400
500
630
710
800
900
1000
1120
1250
1400
Transportation lugs
Support bracket
Dimensions
D
[DN]
A81.004
A81.005
15 dB(A)
[mm]
350
400
500
600
650
900
1100
1200
1400
1600
1700
1900
1900
1900
2500
Connections
L
25 dB(A)
[mm]
350
400
500
600
650
900
1100
1200
1400
1600
1700
1900
1900
1900
2500
15 dB(A)
[mm]
550
600
750
950
1100
1800
2050
2200
2700
2600
3200
3500
4000
4250
5000
H
25 dB(A)
[mm]
950
1050
1550
1600
2000
2800
3300
3500
4100
4200
4900
5500
6000
6500
7500
Page 1 of 1
[mm]
30
30
30
30
30
33
33
33
33
33
33
33
39
39
39
A81.003
[mm]
R 1/2"
R 1/2"
R 1/2"
R 1/2"
R 1/2"
R 3/4"
R 3/4"
R 3/4"
R 3/4"
R 3/4"
R 3/4"
R 3/4"
R 1"
R 1"
R 1
3)
15 dB(A)
[kg]
17
22
36
55
94
219
330
398
588
689
910
1158
1242
1266
2348
25 dB(A)
[kg]
28
36
68
89
161
338
514
611
881
1090
1369
1784
1827
1910
3481
Main dimension
Flue gas silencer

Reduction of the total sound pressure level at the chimney
opening around 15 dB(A) or 25 dB(A) 1)
DA125
Version 6 (02/08)
Additional dimensions for installation of the flue gas silencer in vertical flue gas line:
Flue gas silencer
[DN]
Anzahl der Tragpratzen

Number of support brackets
2)
125
160
200
250
315
400
500
630
710
800
900
1000
1120
1250
1400
Dimensions
B1
[mm]
100
100
100
100
100
100
100
150
150
150
200
200
200
200
200
[-]
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
References Sound pressure level caused by flue gas noises from a boiler system see technical information TI032.
B2
[mm]
100
100
100
100
100
100
100
150
150
150
200
200
200
200
200
Dimensions with 1 % tolerance; indication of weight with 3 % tolerance.
Material: steel or stainless steel possible.
Resistance on flue gas side max. 2 mbar.
Flue gas silencer must be suspended (lifting lugs can be used) or supported. For horizontal installation up to a nominal width of DN
500, it is possible to fasten the flue gas silencer via a firmly mounted flue gas line.
1)
Insertion attenuations of 15 dB(A) or 25 dB(A) are expected values.
2)
Nominal diameter for pipe connection according to DIN 24154 part 4.
3)
Pipe thread according to DIN 2999.
Page 2 of 1
Feed water tank FT.C

for feed water (Full deaeration - trickle deaeration device) 0,5 bar gauge pressure
DA019

Lifting equipment to be fastened here, only
B30.501
Connection for extraction
B30.521
Connection for Draining
B30.504
Connection for Heating-up steam
B30.523
Connection for negative pressure safeguard valve
B30.506
Connection for oxygen-free, directly returning
B30.525
Connection for Pressure safeguard valve
condensate option
B30.508
Connection for Chemical dosing
B30.528
Connection for Overflow valve option
B30.510
Connection for Pump idling option
D05.001
Inspection openings steam and water side
B30.512
Connection for deaeration device
D06.002
Lifting lug
B30.519
Connection for sample extraction
B30.520
Connection for level control
Page 1 of 2

for feed water (Full deaeration - trickle deaeration device) 0,5 bar gauge pressure
DA019


Operating weight
Maximum weight
Type
[kg]
[kg]
[kg]
FT.C 10
1938
10128
13441
1)
Dimension(s)
L1
L2
L3
L4
L5
L6
L7
L8
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
5570
3200
3102
3060
2860
2660
2660
L9
L 10
L 11
L 12
L 13
L 14
L 15
L 16
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
1410
1095
1135
210
985
985
835
L 17
L 18
L 19
L 20
L 21
B1
B2
B3
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
690
690
158
1931
1100
900
B4
B5
B6
H1
H2
H3
H4
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
951
893
1909
1300
225
50
1800
Dimension(s)
Dimension(s)
Dimension(s)
Connection for
B30.501
2)
B30.504
2)
B30.506
2)
B30.508
DN
[mm]
100
40
1/2
PN
[bar/120C]
16
40
16
Connection for
B30.519
3)
B30.520
3)
B30.521
3)
B30.523
3)
B30.510
B30.512
2)
550
2)
B30.525
DN
[mm]
3/8
1/2
1 1/2
50
80
PN
[bar/120C]
16
16
16
40
16
1)
2)
3)
Pipe thread according to DIN 2999
Page 2 of 2
2)
2)
B30.528
2)
Trickling dearator module TDM

for 0,5 bar gauge pressure
DA015

Lifting equipment to be fastened here, only
B30.034
Non-return valve
B30.131
Shut-off valve (throttle cone)
B30.035
Non-return valve
B30.503
Connection for vapours
B30.064
Transport or assembly lug from size TDM20
B30.562
Connection for oxygenic, unpressurized condensate
B30.130
Control valve (magnetic)
B30.563
Connection for make-up water
Trickling dearator module TDM

Operating weight
Maximum weight
Type
[kg]
[kg]
[kg]
TDM 10
141
148
461
Dimension(s)
Connection for
1)
B30.503
H1
H2
H3
[mm]
[mm]
[mm]
[mm]
[mm]
DN
[mm]
32
1350
305
240
750
550
PN
[bar/120C]
10
1)
2)
Page 1 of 1
2)
Technical Information
Requirements for operation of high-pressure boiler systems

without constant supervision
High-pressure steam and hot water boilers
TI012
Version 3 (08/08)
General
According to EC agreements, the sale and distribution of CE-designated products may not be restricted or obstructed (see
also Notes on "Guideline for the implementation of the Directive adopted according to the new concept and the overall concept" also known as the "New Approach" for short - online at
http://ec.europa.eu/enterprise/newapproach/legislation/guide/index.htm). Additional measures in individual countries
aimed at the protection of employees or of the environment are allowed, but may not lead to any changes to the product.
For shell boilers and quick steam generators, this means that, with suitable equipment and corresponding test requirements,
operation without constant supervision is specified by the manufacturer. Individual countries, however, may lay down uniform, equal test requirements and test periods that are as long as possible for products which are technically the same or
similar.
It should be noted that if applicable operation without constant supervision requires a permit and that this must be clarified
with supervisory authorities and/or monitoring organizations.
In compliance with authoritative guidelines relating to the Pressure Vessels Directive 97/23/EC, this Technical Information
sheet describes what the requirements for operation without constant supervision are in terms of the boiler and the system.
Boiler-related requirements for operation without constant supervision
Loos International equips its high-pressure steam and hot water shell boilers on the basis of EN 12953 Part 6 until 8. Quick
steam generators comply with TRD (Euipment), EN 12953 Part 8 (Safety valve) and EN 12953 Part 7 (Burners). For all
boilers, operation without constant supervision is provided for by Loos International and is possible for maximum 72 hours.
The preconditions for operation without constant supervision are compliance with the requirements for the boiler, feed and
make-up water in accordance with Operating Instructions B002 (Steam Boilers) or B004 (Hot Water Boilers) and with those
for regular inspections for high-pressure boilers in accordance with the Operating Instructions B006, B008, B009 or B011
(depending on boiler type).
Operating, maintenance and inspection work on the boiler system by the operating and maintenance staff are carried out on
the basis of check lists in the Operating Instructions B001, B005, B007 (depending on boiler type). In accordance with operation without constant supervision, the shortest inspection periods are specified as 3 days (i.e. 72 h). In addition to these
checklists for operation, the Operating Instructions for the individual components must be complied with.
In order to make the best use of the period of 72 hours for operation without constant supervision and not to have to visit the
boiler more frequently for operating tasks, it is recommended that certain equipment parts are automated. For example, on
the steam boiler: with manual blowdown (see Operating Instructions K005), the valve must be operated several times a day,
depending on the water characteristics. If an automatic blow-down system is connected (see Operating Instructions G353 or
G354) with an LBC Loos Boiler Control, this is no longer necessary. Functional checks, however, are necessary for both
versions every 72 hours.
Additional options, such as, for steam boilers, a separate electrode for the maximum water level, a desalting device and / or
a conductivity transducer can be fitted if required.
System-related requirements for operation without constant supervision
System-related requirements for operation without constant supervision depend on the national and / or local regulations.
Structural requirements such as the need for a separate boiler house or minimum opening sizes for vent and aeration openings must be taken from the local and / or national regulations. You will also find general instructions in our Technical Information sheet TI 024.
Organizational requirements such as the appropriate training of the operating and maintenance staff must be taken from the
local and / or national regulations.
Page 1 of 3

TI012
Version 3 (08/08)
The following chapters describe system-related requirements for operation without constant supervision aimed at protecting
the boiler, the boiler system and people. The precise requirements must be taken from the local and / or national regulations.
The necessary monitoring devices must be generally suitable for this and must have all the necessary permits.
3.1
Monitoring of make-up water
The following measuring devices are required:

Substance
Measuring device
Comment
Make-up water containing

salt
Hardness measurement, e.g. using

the LWA Loos Water Analyzer (see
Operating Instructions I012)
Limit value based on Operating Instructions B002

and B004 at 0.1dH or 0.02 mmol/l (see Operating
Instructions G442 when using monitoring on the
basis of hardness with LSC Loos System Control)
Low-salt and salt-free

make-up water
Conductivity measurement e.g. using

the CST 1 conductivity transducer
(see Operating Instructions I008) or
CST 2 (see Operating Instruction
I014)
Preset limit value at Loos International

150 S/cm (see Operating Instructions G440 when
using foreign body monitoring based on conductivity
with LSC Loos System Control)
Oils, fats, acids, alkalis, sea

If monitoring necessary: See Chap. 3.2
water, etc.
If limit values are exceeded, the flow of make-up water to the feed water container must be interrupted, for example, using a
solenoid valve.
3.2
Monitoring the condensate flows
Possible leaks of oil, fat, hardness or other foreign matter, such as acids, alkalis, sea water etc. via condensate into the
water circuit require automatic continuous monitoring of the condensate circuit. Separate condensate circuits with different
criteria should be monitored individually and equipped with corresponding switchover devices.
If the permitted limit values are exceeded, the condensate flows must be rejected, for example, via drain-off devices.
The following measuring devices are required:
Substance
Measuring device
Comment
Oil
Turbidity measurement
Preset limit value at Loos International:
Fat
Turbidity measurement
Warning if 3 ppm is exceeded and rejection of condensate flows over 5 ppm (see Operating Instructions
G441 when using a turbidity alarm in combination
with an LSC)Loos System Control
Hardness
Conductivity measurement e.g. using the

CST 1 conductivity transducer (see Operating Instructions I008) or CST 2 (see Operating Instruction I014)
Acids / alkalis
Sea water
All of these substances affect conductivity.

Preset limit value at Loos International
CST 1 conductivity transducer (see Operat150 S/cm (see Operating Instructions G440 when
ing Instructions I008) or CST 2 (see Operusing foreign body monitoring based on conductivity
ating Instruction I014)
with LSC Loos System Control)
CST 1 conductivity transducer (see Operating Instructions I008) or CST 2 (see Operating Instruction I014)
These requirements are not absolutely necessary as long as there is no danger of a slump.
Page 2 of 3

TI012
Version 3 (08/08)
If the monitoring mentioned under 3.1 and /or 3.2 only takes place in or after the feed water container, the firing must be
switched off and locked if the permitted limit values are exceeded.
Loos International does not recommend this situation, since in the event of a collapse in individual flows the total system is
contaminated and is no longer operable, since the complete water circuit must be replaced.
3.3
Safety shutoff device in the fuel line
A suitable fuel safety shutoff valve must be provided in the fuel line.
The location, in the case of gas, should be outside the boiler installation room and, with oil, in the near from the oil storage
container.
If the fuel safety shutoff valve in combination with further shutoff device encloses fuel in areas, the content of which expands
with heat, these areas must be secured to prevent an unpermitted rise in pressure.
If the fuel safety shutoff valve is located in the open air, these valves must be suitable for the stresses affecting them (freezing, moisture, etc.).
With hand operated safety shutoff valves a fast and safe access and operation must be assured.
Electrically headed safety shutoff valves must be closed without current.
3.4
Emergency shutdown device
Emergency shutdown devices should be located outside the boiler installation room in such a way that they are easily accessible and easy to trigger.
Emergency shutdown devices must switch off the power circuits of the electrical operating equipment of the firing system in
the event of danger. For this, the boiler safety chain incorporates the facility to loop in an emergency shutdown contact.
If further signals, for monitoring basic dangers in the boiler house, for example, such as fire alarms, are to be incorporated,
these must be grouped together by the client into an emergency shutdown contact in accordance with the valid rules and
regulations for emergency shutdown devices and looped into the boiler's safety chain.
Page 3 of 3

Minimum temperature on the medium side as a function of sulphur content in fuel
TI014
Version 4 (10/07)
1.
1.1
Water vapour dewpoint of flue gases
The water vapour from flue gases is formed from the hydrogen bound in the fuel, the water content of the fuel and the humidity in the air. If an unsaturated flue gas/water vapour misture (damp flue gas) is cooled, the concentration of the water
vapour remains constant until a particular temperature is reached. Below this temperature (dewpoint temperature), part of
the water vapour is elimited as condensate. As the surplus air increases, the water vapour is diluted further and the dewpoint
becomes lower.
60
Gas
Water dewpoint of flue gas [C]
55
50
Light oil EL
45
Heavy oil;
sulphur content > 1.0 % by weight
40
35
1,00
1,05
1,10
1,15
1,20
1,25
1,30
1,35
1,40
1,45
1,50
0,0
1,0
2,0
2,9
3,7
4,4
5,1
5,7
6,3
6,8
7,3
Air coefficient [-]

Oxygen content [%]
Diagram 1: Water vapour dewpoint of the flue gas for different fuels (gas according to DVGW G260; light oil according to
DIN 51603 Part 1; heavy oil according to DIN 51603 Part 5)
Page 1 of 4

TI014
Version 4 (10/07)
1.2
Acid dewpoint of flue gases
The flue gas also contains substances which can dissolve in water. Particular dangers are caused by acidifiers, which can
cause corrosion of heating surfaces and flue gas lines.
The level of the acid dewpoint is influenced by sulphur trioxide SO3, sulphur dioxide SO2 and carbon dioxide CO2, which
form acids in combination with water, and also hydrochloric acid (HCl) and hydrofluoric acid (HF). Since natural gas H and
natural gas L do not contain acidifiers, there is no acid dewpoint for these fuels.
For the fuel sulfur-poor light fuel oil (maximum sulfur content: 50ppm) the acid dew point runs due to the small sulfur content
in the fuel approximately equal the water dew point of light oil (see diagram 1).
The substance which determines the level of the acid dewpoint is primarily sulphure trioxide SO3, which combines with water
vapour to form sulphuric acid H2SO4. The sulphure trioxide content in the flue gas is created to a minor extent from the oxidation of the combustion product sulphur dioxide SO2 ; However, the sulphur trioxide content is mainly influenced by the
sulphur content in the fuel and the type of combustion and flue gas circulation. In addition, the oxygen supply via the surplus
air (increasing SO3 formation through higher air surplus) and absorptive capacity of flue dusts and deposits (which act as
catalysts for the formation of SO3) also play a part.
150
Heavy oil; sulphur content 3.0 % by weight
Acid dewpoint of flue gas [C]
145

140

135
130
125
Light oil
Basis: SO2 / SO3 conversion rate: 1%
120
1,00
1,05
1,10
1,15
1,20
1,25
1,30
1,35
1,40
1,45
1,50
0,0
1,0
2,0
2,9
3,7
4,4
5,1
5,7
6,3
6,8
7,3
Air coefficient [-]

Oxygen content [%]
Diagram 2: Acid dewpoint of flue gas for different fuels (light oil according to DIN 51603 Part 1; heavy oil with sulphur content 1.0 % by weight according to DIN 51603 Part 5; heavy oils with higher sulphur content: acid dewpoint on basis of sulphur content)
Page 2 of 4

TI014
Version 4 (10/07)
2.
Minimum temperatures on the medium side as a function of sulphur content in

fuel
The following statements apply for the combustion of:
gases according to DVGW G260
light oils according to DIN 51603 Part 1
heavy oils according to DIN 51603 Part 5
The minimum temperatures on the medium side are influenced both by the level of the water vapour dewpoint and also be
the level of the acid dewpoint.
The graphs of the water vapour dewpoint (occurrence of corrosion if the temperature falls below the water vapour dewpoint)
shows the following requirements for minimum temperatures, which apply in general:
Return flow temperature for single-flue hot water boiler at least 50C, for double-flue hot water boilers at least 60C
Supply flow temperature for hot water boilers at least 70C
Feed water temperature for steam boilers at least 70C
Water temperature at entry of non-alloy flue gas heat exchangers in steam and hot water boilers of at least 60C
With fuels with a sulphur content greater than 0.2 % by weight in the fuel, both the water vapour dewpoint and the acid dewpoint must be taken into account. If the conversion temperature of the heating surfaces falls below the acid dewpoint, the
water and sulphuric acid H2SO4 components contained in vapour form in the flue gas condense and moisten the heating
surfaces, which causes corrosion.
Maintaining the minimum temperatures on the medium side given below reduces corrosion on the heating surfaces to an
uncritical degree.
Minimum temperature [C]
130
120
110
100
90
0,0
1,0
2,0
3,0
4,0
5,0
Sulphur content in fuel [% by weight]

Diagram 3: Minimum temperatures on the medium side as a function of the sulphur content in the fuel
The minimum temperatures determined from the above diagram as a function of the sulphur content (> 0.2 % by weight) in
the fuel apply as minimum requirements for
the mean medium temperature for hot water boilers, where:

mean medium temperature = ( supply flow temperature + return flow temperature ) / 2
the medium temperature for steam boilers (see TI 001 (saturated steam temperatures))
the feed water temperature for high-pressure steam boilers at the entrance into the flue gas heat exchanger
Page 3 of 4

TI014
Version 4 (10/07)
3.
the water temperature at the intake into the non-alloy flue gas heat exchanger
Special characteristics in the case of different fuels
If there is any deviation from the above-mentioned fuel standard for gas, the following must be taken into account:
the gas must be dry (< 60% relative humidity at operating temperature)
water dewpoint of gas: according to DIN DVGW G260, i.e. maximum ground temperature at the pipe pressure in
question
gas must be free from pollutants
In addition, the following applies for special gases:

1. Combustion of biogas / landfill gas (qualities on the basis of DVGW G262 Table 3):
proportion of sulphur and sulphur compounds in the gas not to exceed 1500 mg/m3 (around 0.1 vol. %)
proportion of chlorine and chlorine compounds in the gas not to exceed 50 mg/m3
proportion of fluorine and fluorine compounds in the gas not to exceed 25 mg/m3
2. Combustion of hydrogen-rich gases (according to DVGW G260 - gas family 1):
return flow temperature with single flame tube hot water boilers at least 60C, or with twin flame tube hot water boilers at least 70 C
forward flow temperature with hot water boilers at least 75C
water temperature at entrance to unalloyed flue gas heat exchanger of steam and hot water boilers at least 70C
Notes:
If operation is not favourable (frequent burner starts, frequent cold starts, fluctuating return flow temperatures), the
minimum water temperatures must be higher.
Other corrosive flue gas components have not been taken into account.
Page 4 of 4
Technical Informations
Requirements for Boiler Installation Rooms Notes on the

installation of boilers and boiler house components
TI024
Version 6 (07/09)
General
This technical information describes the requirements for boiler installation rooms and contains notes on the installation of
boilers and boiler house components for steam, superheated steam, warm and hot water boiler systems. It is intended to
provide assistance to planners of installation rooms and buildings. All the relevant national and local regulations and
applicable standards should also be followed.
Basic requirements for the installation room
The following basically requirements for the boiler room must be met:
The boiler system may only be installed in a room that meets the local regulations for the installation of boiler systems.
The installation room must be kept clean and free from dust and dripping water. The inside temperature must be
between 5C and 40C.
Unauthorised persons must be forbidden to access the boiler room through permanent, clearly visible notices.
Depending on the boiler parameters(water content, pressure, capacity), less strict installation or supervisory regulations
may be applicable, depending on the national regulations.
Sound insulation requirements must be met in accordance with local regulations.
The control cabinets must be installed in such a way that no vibrations or shaking of the system components can be
transmitted to the control cabinets. Installation must be carried out in areas which protect the control cabinets against
excessive radiated heat and which safely allow access in situations which could be dangerous.
Free access to inspection openings on boilers and plant components must be ensured.
2.1
Requirements on the building
The following requirements on the building must be met:
The place of installation must be designed in such a way, in terms of construction, that vibrations caused by the process
cannot cause any damage to buildings or neighbouring systems.
The structural loading of the building shell must be taken into consideration for all fixings.
Every boiler installation room must have n external wall or ceiling surface that is if possible continuous and clear,
totalling at least 1/10 of the ground surface area (or in accordance with local requirements) which, in the event of excess
pressure in the boiler installation room, will give much more easily than the other enclosing walls.
The opening for brining equipment into the boiler installation must be made in accordance with the dimensions of the
individual components. Suitable lifting equipment must be provided in the boiler installation room for moving heaving
equipment.
The clear height and width of all surfaces that can be walked on must be sufficient. Access to the system must be
guaranteed in accordance with the local regulations. If the clear height of the installation room is smaller than the
required height, for construction reasons, the minimum height must be agreed with the local authorities.
Suitable, clearly marked emergency rescue routes must be provided.
The boiler installation room, especially in the area of the valves and safety equipment, and the emergency rescue
routes must be well lit.
The parts of the system that are to be operated must be easily accessed and there must be sufficient space to pen
doors (including inspection openings).
2.2
Requirements on the foundation
The following requirements on the foundation must be met:
Care should be taken to ensure that the floor in the installation room is completely level (evenness tolerance: in
accordance with DIN 18202) and of a sufficient loadbearing capacity.
Page 1 ofn 7

TI024
Version 6 (07/09)
Possibly existing ground ducts must be covered and equipped with drainage systems.
In calculating the loadbearing capacity of the foundation, the maximum operating weight of the relevant components
must be taken into account. In determining the operating weight, additional attachments (e.g. control cabinet, burners,
sound attenuators, flue gas pipes, etc.) must also be taken into account and their weights included. The operating
weight corresponds to the weight of the components when filled.
The operating weight of boilers must be taken by the foundations in the area of the front and back feet. Care should be
taken to ensure that the rear boiler foot (seen from the burner side) is designed as the fixed point on the longitudinal
beam. The front boiler foot is designed as a loose bearing point, i.e. the boiler expands forwards when it heats up.
Each component must be levelled when it is installed.
If a separation between the installation surface and the system is required due to structure-borne sound, sound
insulation strips must be positioned under the system before it is installed.
If boiler or plant components are to be installed on a bearing structure, suitable spring systems should be used for
bearing and absorption of vibrations.
2.3
Aeration and vent openings
Incoming air must be free from foreign bodies; it may not contain dust or corrosive elements, such as solvents or coolants,
for example.
2.3.1
Layout of openings
The aeration openings should ideally be located at the back of the boiler. If this is not possible, for structural reasons,
deflector plates or metal ducts must be installed within the boiler installation room to divert the intake air. When planning the
aeration openings, the position of system components that are sensitive to frost (e.g. water treatment systems) must be
taken into account to ensure that they are not installed directly in the flow of incoming air. In addition, the aeration openings
must be installed in the boiler installation room in such a way that the flow of incoming air does not pass across boiler doors
or reversing chambers (to avoid condensation).
Vent openings must also be provided. Aeration openings should be 500 mm above the boiler room floor and vent openings
should be located at the highest point in the installation room. Cross ventilation must also be provided.
2.3.2
Determination of size
Aeration and vent openings must be designed in such a way that the pressure in the boiler room is 0 mbar. We provide the
following calculation formulae as a non-binding recommendation. It is essential that the system installer obtains the
agreement of the competent planning or building authority. Additional incoming air consumption units (e.g. compressors)
must be taken into consideration when determining the size of the openings.
Group classification by thermal capacity:
Aeration opening cross-section:
GR 1
2000 kW
A GR 1
300 + [(Q 50) x 2,50]
GR 2
> 2000, 20000 kW
A GR 2
5175 + [(Q 2000) x 1,75]
GR 3
> 20000 kW
A GR 3
36675 + [(Q 2000) x 0,88]
Explanation of symbols:
A GR
= Clear cross-section in cm
= Thermal capacity in kW
Ratio between sides maximum 1 : 2

Vent cross-sections are always 60% of aeration cross-sections.
The cross-sections are net cross-sections.
Page 2 ofn 7

TI024
Version 6 (07/09)
If the combustion air is transported to the burner via air intake channels, aerodynamic flow and sufficient dimensioning with
regard to pressure loss must be ensured.
2.3.3
Frost protection
If there is a risk of low outside temperatures or in the case of boiler installation rooms in which the full insulation of all system
components and fittings only allows minimum radiation of heat and thus no heating of the boiler house, it is necessary to
take steps to pre-warm the incoming air (e.g. using heating registers in the aeration opening) and to prevent frost.
2.3.4
Electrical integration
With adjustable aeration flaps, firing may only start if the aeration flap is completely open (potential-free feedback to the
boiler control via safety limit switches). Aeration flap controls must be provided.
2.4
Special requirements for open air installation
If boilers are installed in the open air, the following additional requirements must be met:
All the components and parts of the system must be suitable for external installation (i.e. suitable material, necessary
protection category, paint / protective coating, etc.).
Sensitive components (burner system, control cabinet, measurement and control equipment, motors, pumps, etc.) must
be protected by a roof against rain and sunshine.
Thermal insulation must be provided in accordance with the conditions in situ.
Cable material and wiring must be suitable for external installation.
If there is a risk of frost, the system components, pipes, pumps and fittings must be provided with background heating.
An effective lightning conductor system must be provided.
Transport of the boiler system
For floor-level boiler transport, means of transport under the base frame may exclusively be placed below the boiler feet.
The use of tank steel rollers under the base frame is inadmissible for floor-level transport. Danger of base frame deflexion!
Burner system
Technical Information TI030 Requirements for a burner system provided by the customer or a burner system provided by
the customer with boiler control provided by the customer for the operation of oil-, gas- and dual-fired steam, heating and
hot water boilers must be complied with. When attaching the burner system and burner components (e.g. silencer hood, oil
circulation module, etc.), care should be taken to ensure that it is easy to open the front reversing chamber door and/or
boiler door and to swivel the burner without any problems. Oil hoses, cables, etc. should be laid accordingly, and the burner
fittings should project at the side. The compensator in the gas regulating line must be installed in the longitudinal direction of
the boiler in order to absorb the axial expansion of the boiler.
4.1
Combustion air
Air should be supplied to the burner system from the boiler installation room in order to allow for fluctuations in the outside
temperature. The maximum temperature fluctuation may not exceed 30 K.
Combustion air temperature:
4.2
minimum:
+ 5C or in accordance with burner manufacturer's instructions
maximum:
+ 40 C or in accordance with burner manufacturer's instructions
Fuels
Facilities for the storage, preparation and supply of fuels must be design and made in such a way that they can be used
without danger and meet the national and local regulations and relevant standards.
For commissioning the burner system it must be possible to measure fuel quantities for each burner and fuel type.
Page 3 ofn 7

TI024
Version 6 (07/09)
4.2.1
Fuel oil
The storage and distribution of fuel must be carried out in accordance with safety requirements. If the fuel supplied is EL fuel
oil, the storage and transport temperature should not be less than 5C; with medium and heavy oils, higher temperatures are
necessary, depending on the viscosity, in order to guarantee that the oil can still be pumped. If necessary, background
heating must be provided for the tank and pipe system.
4.2.2
Gas
A device for safe drainage under pressure must be installed upstream of the gas regulation module.
Liquid gas must be available in vapour form at the gas regulating module. The safeguard pressure at the transfer station
may not be greater than the maximum permitted gauge pressure at the gas regulating module.
Flue gas system
The following paragraphs contain recommendations for the design of flue gas systems to ensure trouble-free operation of
combustion systems. In case of non-observance of these regulations, serious operating troubles up to deflagration can occur
during firing operation. These are often acoustic faults, impairment of combustion stability, excessive vibration of
components or their components respectively. Low NOx firing systems must be assessed as critical with regard to these
operating troubles due to their combustion control. Thus, planning and construction of the flue gas system requires particular
technical elaboration.
The flue gas system usually consists of a connection piece between heat generator and the vertical part of the flue gas
system and the vertical flue gas system itself (chimney).
The following requirements must be met when designing and constructing the flue gas system:
Flue gas systems must be designed in accordance with the national and local regulations as well as the applicable
standards. General requirements on flue gas systems at and inside of buildings are specified in the DIN EN 1443
standard. The design of the flue gas systems must comply with the locally applicable building laws as well as the DIN V
18160 standard. For freestanding chimneys, the DIN 1056, DIN 4133 and DIN EN 13084-1 standards are applicable
besides the building laws. Specifications for fluidic dimensioning must be gathered from the DIN EN 13384 standard for
flue gas systems at and inside of buildings or DIN EN 13084-0 for freestanding chimneys.
Flue gas ducts must be made from non-flammable building materials and must be resistant to the effects of flue gas and
heat. The material for the flue gas system must be suitable for temperatures up to 350C.
When determining the material of the flue gas system, the composition of the combustion gases must be taken into
account in order to prevent damage or soiling of the system components in contact with flue gases.
The flue gases must be directed directly towards the chimney in a gas flow-optimizing way (e.g. on a short and rising
path with little deviations).
Each boiler must be equipped with a separate chimney pass. The flue gas line and the chimney are dimensioned according
to details provided by expert companies and refer to a pressure of +0/-1 mbar (for boilers with thermal capacity 2 MW: +
0/- 0.5 mbar) at the boiler or flue gas heat exchanger flue gas connection. The systems heat expansion must be taken into
account.
Diversions in connection pieces must be executed in a favourable fluidic way by means of bends or guiding plates.
Connection pieces with several diversions should be avoided as they might have a negative influence on airborne and
structure-borne sound as well as the start-up pressure impulse. Sharp-edged transitions between rectangular
connection flanges and the connection pipe should be avoided. As applicable to possibly required reductions /
extensions, the transition angle should not exceed 30.
Several fireplaces may only be connected to a common flue gas system (chimney, flue gas pipe) if their design ensures
that they are suitable for this operating mode and meet the following requirements:
The system is dimensioned for proper flue gas discharge in any operating mode.
The entry of flue gases in switched-off fireplaces in pressurized operation (e.g. by tightly closed flue gas flaps)
is prevented.
The furnace pressure conditions remain constant in all connected heat generators in all operating modes.
Page 4 ofn 7

TI024
Version 6 (07/09)
The minimum flue gas velocity Wmin acc. to the DIN EN 13084-1 standard is taken into account or, simplified,
Wmin = 0.5 m/s.
However, merging of flue gas streams should be avoided as it causes a slight negative pressure in the chimney if only a
small portion of the chimney capacity is used (e.g. when only one heat generator is operated). In that case the flue gases
do not fill the chimney completely any more and cold air can enter the chimney. The resulting cooling of flue gases can
bring about soot formation, chimney fouling and fire hazard in the chimney. However, if the merging of flue gas streams
cannot be avoided, the flue gas streams must be guided parallel and insulated from each other by an insulating plate in a
short section of the flue gas system in order to avoid interaction of the flue gas streams.
The following heating appliances must not be connected to flue gas systems serving several heating appliances:
Furnaces operated with liquid gas
Fireplaces with fans unless all fireplaces are installed in the same room
Connection pieces must be entered in the chimney upwards in a gas flow optimising way if possible (with an angle of
45). In case the chimney serves several heating appliances, connections located opposite or on the same level must
be avoided. Possibly existing caps on chimney outlets must ensure free discharge of the flue gases into the free airflow.
Any occurring condensates must be discharged without any obstructions on the complete length according to the local
regulations (e.g. ATV (Sewage Technology Association) Bulletin No. 251) and disposed of in accordance with the local
regulations.
The chimney must be equipped with cleaning openings acc. to the local regulations (e.g. DIN 18160-1 and DIN 18160-5
standards, IVS (Industrial Association for Steel Chimneys) Guideline No. 105), possibly in coordination with the
competent chimney sweeper or chimney sweeper master craftsman).
The chimney may be positioned directly on the flue gas heat exchanger if the load and the horizontal forces (e.g. wind
forces) do not have any effect on the heat exchanger. A separate support for the chimney must be provided. In order to
stop rain from entering and thus to prevent corrosion in the flue gas heat exchanger, the chimney must be provided in
this case with a cover.
The chimney (e.g. with compensator) must be separated from the boiler/flue gas heat exchanger system in order to
prevent any structure-borne sound.
In the event of a standstill and minus temperatures outside, the danger of frost damage must be prevented.
If a flue gas valve is incorporated into the flue gas system, it is essential that a safety limit switch "OPEN" is
incorporated into the boiler control. It must only be possible for firing to start if the limit switch reports that the flue gas
valve is completely open. Due to the setting time of the flap drives, pressure or temperature drop in the boiler is
possible. The "SHUT" position at the flue gas valve must be set in such a way that the flue gas valve never completely
closes. This will prevent any damage from accumulated heat at the attached burner. To ensure that any accumulated
heat can be safely removed, it is essential that there should be a sufficient vacuum behind the flue gas valve (on the
chimney side) as soon as the assigned burner switches off. Alternatively, if the flue gas valve closes tightly, an opening
to remove the accumulated heat should be provided in the direction of flow to the flue gas valve.
Observe that the heat exchanger bundles of double-flue boilers with single-flame tube operation and down-line
economizers or flue gas condensers are separated on the flue gas side in such a way that the flue gases are well
directed to the flue gas system. If the two flue gas lines from the double-flue boiler are connected, the pressure at this
point must amount to + 0 / - 1 mbar (at full-load with single-flame operation). If this is not the case, sealing air blowers
will be necessary for each burner.
6
6.1
Piping
Piping design
Pipes must be laid in accordance with the national and local regulations and relevant standards, taking into account the
pressure losses and flow speeds.
Suitable materials (for the max. permissible temperatures (safety temperatures) of the system components) and
accessories (e.g. piping supports) must be used.
Page 5 ofn 7

TI024
Version 6 (07/09)
When installing a flue gas condenser, the downstream flue gas system must be suitable for condensation operation
(stainless steel design).
6.2
Piping installation
All supply and discharge lines must be laid in accordance with the regional applicable regulations as well as the
recognised engineering rules.
The thermal expansion of pipes and system components (boiler, flue gas heat exchanger) must be taken into account
for piping installation.
Lines must be laid in a stress-free way and they must not apply any forces or moments on the system components.
Hot pipes must be marked and surrounded by an effective touch guard so that injuries by touching the hot pipes are
excluded.
Discharge into pump sumps, drain channels etc. must be designed in such a way that the discharged water can be
controlled.
6.3
Vent and drainage pipes
Pipes must be installed over the shortest route and with drainage facilities at the lowest point and vent facilities at the
highest point.
Drainage and desalting, emptying and blow-down pipes must be laid separately and sloping to the blow-down,
expansion and cooling device. The waste water must be cooled before passing into the sewage network in accordance
with local regulations.
If the blow-down pipe is taken more than 1 m upwards, the blow-down pipe must be drained at the lowest point before
every blow-down procedure. It is recommended that stainless steel pipes are used as the material for the blow-down
pipe because of the higher load on the pipes.
Observe that blow-down lines of low-pressure boilers are pulled upwards max. 2 m from the boiler connection (drain).
Pressure safeguard blow-down pipes or vent pipes at the blow-down, expansion and cooling device must be taken so
that they open safely into the open air, must be protected against the penetration of rainwater and dirt and drained at
their lowest point. In the case of warm and hot water boiler systems, an expansion vessel at the pressure safeguard
blow-down pipe is necessary in order to separate the water-steam mixture.
Pressure safeguard blow-off lines may only be brought together with other lines in exceptional cases and with the
corresponding calculated evidence.
Drainage connections on the flue gas side of boilers (e.g. flue gas chambers) and plant components must be equipped with
a water pocket of approx. 10 cm to avoid flue gas emission. The drainage pipes (stainless steel) must be guided via a
neutralisation. In order to prevent accidental backflow it is prohibited to combine them with pipes conveying other media.
The starting line for the boiler must be incorporated into the pipeline network in such a way that each boiler can safely
emit steam into the open air via the steam shutoff valve during the start-up procedure.
Installation of fittings and system components
When installing fittings and system components, the following requirements must be met:
Fittings must be installed without tension. Installation mistakes may not be rectified by violently tightening the flange
screws.
Flange seals must be checked for cleanliness and proper fit.
Fittings must be drained if necessary to prevent water impact.
When fitting the individual system components and fittings, make sure that they can be operated and that the direction
of flow is as indicated.
Page 6 ofn 7

TI024
Version 6 (07/09)
The feed water pipework must be direct and suitable for the water flow. The feed pumps must be located right by the
feed water container. When erecting the feed pumps, the minimum positive suction head of the pump must be
maintained.
In the case of condensing boilers, sufficiently dimensioned neutralisation systems must be used in accordance with the
valid local regulations.
Screws and nuts for flange connections must be designed for the max. gauge pressures and temperatures that might
occur and they must be made of suitable material acc. to international, national or local regulations (e.g. material No.
5.6 for screws or material No. 5.2 for nuts).
In multi-boiler steam plants hydraulic decoupling of the individual boilers via non-return valves (e.g. at the steam
distributor) is mandatory to avoid interaction of the boilers (pressure charging).
Assembly of Measurement and Control Technology
The following requirements must be observed when installing measurement and control technology components:
Observe the mounting position and conditions (e.g. max. ambient temperature) and the necessary inlet and outlet paths
of the sensors (observe the operating instructions of the respective devices for this).
When installing sensors in flue gas lines observe that they must be mounted in pipes that are constantly ascending or
running vertically up (mandatory with limiter devices). Possibly occurring condensate must be discharged without any
obstructions.
If any water seals are installed upstream of sensors they must be filled with distilled water.
Observe during installation that sensors must accessible for commissioning and maintenance.
Page 7 ofn 7
Technical information
Connection to construction-side central control systems

Valid for boiler systems with up to 4 boilers
TI034
Version 3 (10/09)
Contents
1
General Information ................................................................................................................................................... 1
Transmission types.................................................................................................................................................... 1
2.1
PROFIBUS-DP............................................................................................................................................................. 1
2.2
INDUSTRIAL ETHERNET............................................................................................................................................ 3
2.2.1
Passive connection (as Server) with application protocol S7 communication via TCP/IP, e.g. from on-site OPC
server ........................................................................................................................................................................... 3
2.2.2
Passive connection (as Server) with application protocol S7 communication via ISO transport connection (H1), e.g.
from on-site OPC server............................................................................................................................................... 3
2.2.3
Passive connection with application protocol AG_SEND/AG_RECEIVE via ISO transport connection (H1) ............... 5
2.2.4
Passive connection with application protocol AG_SEND/AG_RECEIVE via ISO-ON-TCP connection (RFC1006)..... 6
2.3
MODBUS-RTU............................................................................................................................................................. 7
2.3.1
Data query, Function Codes......................................................................................................................................... 7
2.3.2
Coils and registers........................................................................................................................................................ 8
General Information
Often, boiler systems are a component part of complex systems (e.g. process systems, power stations, building complexes,
etc.), which possess higher-level command systems. Depending on requirements, various transmission types (bus systems,
networks) and connection structures are used for signal transmission to the command systems. The standard boiler system
delivery can contain the transmission type PROFIBUS-DP, ETHERNET or MODBUS-RTU, depending on the selected
option.
Transmission types
The following section(s) describe(s) the presettings, information and data required for processing orders of the selected
transmission types.
Note: Order-related data (measured values, operating signals, fault messages, possibly external requests,
etc.) is documented in a parameter list and a datapoint list, which is located in the control cabinet. An advance
delivery of the parameter list or datapoint list is available on request by agreement with the responsible project
officer.
2.1
PROFIBUS-DP
Presettings:
General description:
Communications processor
CP342-5
Page 1 of 8

TI034
Version 3 (10/09)
DP address:
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Mode of operation
Baud rate
Bus profile
Highest PROFIBUS - address
GSD file
11
12
13
14
15
DP-Slave, passive
1,5 MBit/s
Standard
126
SIEM80D6.GSD
During the bus profile attitude "standard" is considered there is no net and line.
DP addresses are only used and assigned when the appropriate control cabinets are part of the standard delivery.
The assignments of the DP addresses to the control cabinet numbers and manufacturer numbers are documented in
the order-related parameter list, which is supplied with the control cabinet.
If different values to the presettings are to be set at the factory (DP addresses, Baud rate or Bus profile), then this must
be indicated to the responsible project officer at the latest 10 working days after the order confirmation arrives.
The GSD file of the communications processor is available on the Internet:
http://support.automation.siemens.com/WW/view/en/113652 (English website)
http://support.automation.siemens.com/WW/view/de/113652 (German website)
A CP 342-5 DP (12MB) Software_Release="V 5.0" with the number 6GK7 342-5DA02-0XE0 is used as the station type.
Bus parameter:
Designation
Value
Tslot Init
Max.Tsdr
Min. Tsdr
Tset
Tqui
Gap - Factor
Retry Limit
Tslot
300 t_bit
150 t_bit
11 t_bit
1 t_bit
0 t_bit
10
1
300 t_bit
Tid2
Trdy
Tid1
Ttr
Ttr typically
Watchdog
150 t_bit
11 t_bit
37 t_bit
22313 t_bit (=14.9 ms)
1129 t_bit (=0.8 ms)
66568 t_bit (=44.4 ms)
officer.
Page 2 of 8

TI034
Version 3 (10/09)
2.2
INDUSTRIAL ETHERNET
An Industrial Ethernet connection to the central command system can be made using various protocols and connections.
The offer or order confirmation lists which protocol is planned for the project / order. The default presettings and necessary
information for order processing are summarised below for the various protocols.
Note: Please contact the responsible project officer for special protocols or special settings not contained in
the list below.
2.2.1
Passive connection (as Server) with application protocol S7 communication via TCP/IP, e.g.
from on-site OPC server
IP addresses are only used and assigned when the appropriate control cabinets are part of the standard delivery.
The IP addresses, subnet mask and router address can be changed on the operating panel. If different values (IP
addresses, subnet mask and router address) to the presettings are to be set at the factory, then this must be indicated
to the responsible project officer at the latest 10 working days after the order confirmation arrives.
The assignments of the IP addresses to the control cabinet numbers and manufacturer numbers are documented in the
order-related parameter list, which is supplied with the control cabinet.
Presettings:
IP-Address:
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Subnetmask
Router
Communication:
Transport protocol
Mode
Application protocol
Physical interface
CPU-Parameter (Slot; Rack)
Adapter
Properties
CP343-1
192.168.0.1
192.168.0.2
192.168.0.3
192.168.0.4
192.168.0.5
255.255.255.0
---TCP/IP
passive, Server operation one direction, no SEND-Requests
S7
Industrial Ethernet
2; 0
2 x RJ45, 2-port-switch integrated
10/100MBaud, Full/Half Duplex, Autosensing/Autonegotiation,
Autocrossover
officer.
2.2.2
Passive connection (as Server) with application protocol S7 communication via ISO transport
connection (H1), e.g. from on-site OPC server
MAC addresses are only used and assigned when the appropriate control cabinets are part of the standard delivery.
Page 3 of 8

TI034
Version 3 (10/09)
MAC addresses are preset by the manufacturer of the communication processor. If different MAC addresses to the
presettings are to be set at the factory, then this must be indicated to the responsible project officer at the latest 10
working days after the order confirmation arrives.
The assignments of the MAC addresses to the control cabinet numbers and manufacturer numbers are documented in
Presettings:
MAC-Address:
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Communication:
Transport protocol
Mode
Physical interface
Adapter
Properties
CP343-1
preset from CP-supplier
ISO (H1)
passive, Server operation one direction no SEND-Requests
S7
Industrial Ethernet
2; 0
Autocrossover
officer.
Page 4 of 8

TI034
Version 3 (10/09)
2.2.3
Passive connection with application protocol AG_SEND/AG_RECEIVE via ISO transport

connection (H1)
MAC addresses are only used and assigned when the appropriate control cabinets are part of the standard delivery.
MAC addresses are preset by the manufacturer of the communication processor. If different MAC addresses to the
presettings are to be set at the factory, then this must be indicated to the responsible project officer at the latest 10
working days after the order confirmation arrives.
The assignments of the MAC addresses to the control cabinet numbers and manufacturer numbers are documented in
Presettings:
MAC-Address:
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
TSAP: (local LSAP)
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Communication:
Transport protocol
Mode
Physical interface
Adapter
Properties
CP343-1
_LBC
_LBC
_LBC
_LBC
_LSC
ISO (H1)
passive connection launch, unspecified connection
AG_SEND/AG_RECEIVE
Industrial Ethernet
2; 0
Autocrossover
officer.
Page 5 of 8

TI034
Version 3 (10/09)
2.2.4
Passive connection with application protocol AG_SEND/AG_RECEIVE via ISO-ON-TCP

connection (RFC1006)
IP addresses are only used and assigned when the appropriate control cabinets are part of the standard delivery.
If different values (IP addresses, subnet mask and router address) to the presettings are to be set at the factory, then
this must be indicated to the responsible project officer at the latest 10 working days after the order confirmation arrives.
The assignments of the IP addresses to the control cabinet numbers and manufacturer numbers are documented in the
order-related parameter list, which is supplied with the control cabinet.
Presettings:
IP-Address:
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Subnetmask
Router
TSAP: (local LSAP)
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Communication:
Transport protocol
Mode
Physical interface
Adapter
Properties
CP343-1
192.168.0.1
192.168.0.2
192.168.0.3
192.168.0.4
192.168.0.5
255.255.255.0
---_LBC
_LBC
_LBC
_LBC
_LSC
ISO_ON_TCP (RFC1006)
passive connection launch, unspecified connection
AG_SEND/AG_RECEIVE
Industrial Ethernet
2; 0
Autocrossover
officer.
Page 6 of 8

TI034
Version 3 (10/09)
2.3 MODBUS-RTU
Modbus addresses are only used and assigned when the appropriate control cabinets are part of the standard delivery.
The assignments of the Modbus addresses to the control cabinet numbers and manufacturer numbers are documented
in the order-related parameter list, which is supplied with the control cabinet.
Presettings:
Modbus RTU Slave-Address:
LBC boiler 1
LBC boiler 2
LBC boiler 3
LBC boiler 4
LSC
Mode of operation
Physical interface
Adapter
Baud rate
Parity
Stop-Bit(s)
X-Gateway Modbus-RTU Slave

11
12
13
14
15
Modbus-RTU-Slave
RS232, RS485 (2-wire-operation)
9 pin SUB-D female connector
9,6kBaud
even
1
officer.
2.3.1
Data query, Function Codes
The Modbus RTU Slave works as a passive node and processes queries to read or write data coming from the Master. The
queries are encoded in the form of function calls (Function Codes, Function Calls). The Slave does not initiate
communication to the Master automatically. Individual states (Coils) can be read or written in by bit or registers by words.
The following Function Codes are supported:
MODBUS function
Function Code
Direction
Read Coil / Read individual bit
Slave--> Master
Read Input Register / Read dataword
Slave --> Master
Write Coil / Write individual bit
Master --> Slave
Write Single Register / Write dataword
Master --> Slave
Page 7 of 8

TI034
Version 3 (10/09)
2.3.2
Coils and registers
The Input and Output buffers are structured according to the following pattern:
Note: Coils are counted from the direction of the MSB, e.g. Coil 1 corresponds to Bit 16 of Register 1.
Register#
Coil#
Buffer
Storage location in the Comment

buffer
1...16
Input Buffer
000...001h
17...32
002...003h
33...48
004...005h
49...64
006...007h
65...80
008...009h
81...96
00A...00Bh
97...112
00C...00Dh
...
...
...
255
4065...4080
1FC...1FDh
256
4081...4096
1FE...1FFh
257...1024
4097...16384
Reserved
1025
16385...16400
Output Buffer
000...001h
1026
16401...16416
002...003h
Available
functions:
1027
16417...16432
004...005h
1028
16433...16448
006...007h
1029
16449...16464
008...009h
1030
16465...16480
00A...00Bh
1031
16481...16496
00C...00Dh
...
...
...
1279
20449...20464
1FC...1FDh
1280
20465...20480
1FE...1FFh
1281...
20481...
Available
functions:
Modbus
- Read Coil (FC1)

- Read Input Register
(FC4)
Modbus
- Write Coil (FC5)

- Write Single Register
(FC6)
Reserved
Note: The order-related assignment of the datapoints to the registers and coils (measured values, operating
signals, fault messages, possibly external requests, etc.) is carried out when the control cabinet is delivered
(datapoint list located in the control cabinet). An advance delivery of the datapoint list is available on request
by agreement with the responsible project officer.
Page 8 of 8

Betriebsanleitung Engl PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Betriebsanleitung Engl PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Version 1 (05/02)

This operating manual is meant for persons operating,

Preface to the Operating Manual

Basic safety instructions

Directive water conditions for hot water boilers

Regular inspections for shell boilers Maximum permitted working pressure

Check list for hot water boiler

Boiler and Boiler components

Shell boiler for producing hot water

Gas regulation module (GRM)

Combustion manager W-FM100

VLT AutomationDrive FC 300

industrial burner WKG80/4-A, version NR (NOX reduced)

Equipment for water and steam supply

Return flow temperature safeguard

Frequency Converter PumpDrive

Equipment for fuel supply and heat recovery

High performance fan

Wet and Dry Conservation

Return flow temperature control with speed controlled lifting pump

Flue gas heat exchanger pump

Performance regulation infinitely variable load request via permanent signal

Return flow shut-off valve, controlled

Switch box components

Operating and Monitoring System TP10

Central Processing Unit CPU313C

Communication Module CP343-1 Lean Industrial Ethernet

Communication Module CP342-5 Profibus DP

Analogue Input Module

Analogue Output Module SM332

Measuring transducer IgT-MU

Universal Frequency Transducer

Proline Promag 50P, 53P

Energy Manager RMS621

Level limiter electrode Type E4B

INSTALLATION INSTRUCTIONS Model 107 vLT / 107 vLHT with weighted

Armatures and servo units

Supape de trecere i reglare - STEVI 425/426

Full-stroke safety valves

Pressure gauge with test stop valve

Inspection openings steam and water side

Gas filter HF 2000

Electric multi-turn actuators SA07.1 - SA 48.1 / SAR 07.1 - SAR 30.1

High performance butterfly valves Series HP111 / HP114

Form operating log book for hot water boiler

After Sales Service Enquiry/Order

Regular Inspections - External Inspections

Regular Inspections - Internal Inspections

Regular Inspections - Water Pressure Test

Project-oriented data sheets from LPK

Requirements for operation of high-pressure boiler systems without constant 3(08/08)

Dewpoint of flue gases

Requirements for Boiler Installation Rooms

Parameter for the Profibus DP Interface

Basic safety instructions

Scope of the Operating Instructions ........................................................................................................................ 2

Use in Accordance with Regulations....................................................................................................................... 2

Operating and maintenance staff................................................................................................................................. 3

Competent person ....................................................................................................................................................... 3

General notes and symbols ......................................................................................................................................... 3

Safety and health protection ........................................................................................................................................ 4

Operating and Maintenance Staff ............................................................................................................................. 6

General Risks and Accident Prevention .................................................................................................................. 6