Alfa Laval

FINAL DRAWINGS LIST

CUSTOMER : Daewoo Shipbuilding & Marine Engineering Co., Ltd.

HULL NO : H-2210

Freshwater Type : VSP-36-125CC / VSP-36-125SWC

No Description Document No. Page Remark

1 Instruction manual for VSP-36-125CC/SWC - 1-1~52

2 Manual for Commender 250 - 2-1~56

3 Manual for Pressure transmitter - 3-1~49

4 Manual for Pneumatic steam converter 4-1~7

5 Manual for Electropneumatic positioner 5-1~8

6 Manual for desuperheating control valve 6-1~14

7 Order specification for VSP-36-125CC - 7-1

8 Order specification for VSP-36-125SWC - 7-2

9 Specification parts list - VSP-36-125CC SPE-N-010451 8-1~2

10 Specification parts list - VSP-36-125SWC SPE-N-010452 8-3~4

11 Material specification 985 13479 8-5~8 Common

12 Dimension drawing, foundation 985 13478 8-9 Common

13 Dimensin drawing, VSP-36-125CC DSME2210-11-15 8-10 VSP-36-125CC

14 P/I Diagram, VSP-36-125CC DSME H2210A-01 8-11 VSP-36-125CC

15 Vertical positioning, highest 985 15033-01 8-12 VSP-36-125CC

16 Vertcal positioning, lowest 985 15034-01 8-13 VSP-36-125CC

17 Assembly scheme, VSP-36-125CC 985 17073 8-14 VSP-36-125CC

18 Mounting drawing/Part list, VSP-36-125CC 985 17233 8-15~20 VSP-36-125CC

19 Dimension drawing, VSP-36-125SWC DSME2210-11-16 8-21 VSP-36-125SWC

20 P/I Diagram, VSP-36-125SWC DSME H2210-01 8-22 VSP-36-125SWC

21 Vertical positioning, highest 985 15031-01 8-23 VSP-36-125SWC

22 Vertcal positioning, lowest 985 15032-01 8-24 VSP-36-125SWC

23 Assembly scheme, VSP-36-125SWC 985 17072 8-25 VSP-36-125SWC

24 Mounting drawing/Part list, VSP-36-125SWC 985 17232 8-26~31 VSP-36-125SWC

25 Technical data, Pump and Motor - 8-32 Common

25 Heat balance for VSP-36-125CC - 8-33 VSP-36-125CC

26 Heat balance for VSP-36-125SWC - 8-34 VSP-36-125SWC

Dept Date Drawn Checked Approved

Marine & Diesel 031124 DKS YHM

No Description Document No. Page Remark
984 70069.00 /
27 Fresh water pump & Condansate pump 8-35~37 Common
984 10230.00
28 Control panel build on frame N-009859/62-03 8-38 Common

29 Arrangement drawing for control panel N-010451-00-00 8-39 Common

30 Electric diagram for control panel N-010451-01-00 8-40~51 Common

31 Feed water treatment build on frame N-009837/38-02 8-52 Common

32 Dimension drawing / Part list, Feed water treatment 985 16184 8-53~54 Common

33 Steam pressure transmitter (PT-SS-01) - 8-55~56 Common

34 Pressure gauge valve 985 20103 8-57 Common

35 Vaccuum switch (PT-E1-01) - 8-58~59 Common

36 Solenoid valve (VA-FR-02) - 8-60~61 Common

37 Strainer (ST-CO-01) - 8-62~63 Common

38 Steam conditioning unit automatic control valve N-010451/54-10 8-64~67 Common

39 Assembly drawing, Air arrangement 985 16458 8-68~69 Common

40 Flow regulating valve - 8-70~71 Common

41 Combined brine/air ejector 984 12230.00 8-72~73 Common

42 T-pice for electrode unit 984 57672 8-74~75 Common

43 Spring loaded valve on feed water line 984 35535.00 8-76~77 Common

44 Spring loaded valve on fresh water line 984 35516.00 8-78~79 Common

45 Solenoid valve 984 23482.00 8-80~81 Common

46 Steel box for spare part kits 9.2.9.2-3 8-82 Common

47 Spare parts kit for VSP-36-125CC SPARES-N-010451 9-1 VSP-36-125CC

48 Spare parts kit for VSP-36-125SWC SPARES-N-010452 9-2 VSP-36-125SWC

49 Spare parts for F.W Generator 985 16721K 9-3~6 Common

Dept Date Drawn Checked Approved

Marine & Diesel 031124 DKS YHM

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Alfa Laval reserve the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement
of this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval company.

3XEOLVKHGE\ Alfa Laval Desalt A/S

Maskinvej 5
DK-2860 Søborg
(Copenhagen) Denmark

© &RS\ULJKW$OID/DYDO'HVDOW
This document and it content must not be copied, reproduced, transmitted or dis-
closed to any third party without consent of Alfa Laval Desalt.

1-2 O-VSP-36.fm
 7DEOHRI&RQWHQWV

6DIHW\,QVWUXFWLRQVDQG:DUQLQJV
1.0.0 Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5

6\VWHP'HVFULSWLRQ
1.0.0 Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
1.1.0 Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
1.2.0 Freshwater Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
1.3.0 Automatic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
1.3.1 Steam Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
1.3.2 Desuperheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
1.3.3 Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
1.3.4 Set Point for Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
1.3.5 Set Point for Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12

2SHUDWLQJ,QVWUXFWLRQV
1.0.0 Starting and Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
1.1.0 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
1.1.1 Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
1.1.2 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
1.2.0 Adjustment of Sea Cooling Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
1.3.0 Stopping the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
1.4.0 Long Term Standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15

0DLQWHQDQFH
1.0.0 Why you need to perform regular maintenance duties . . . . . . . . . . . . . . . . . page 17
1.1.0 Overhaul Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
1.2.0 Maintenance of Separator Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
1.3.0 Maintenance of Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
1.4.0 Maintenance of Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
1.5.0 Renewal of Plate Heat Exchanger Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . page 21
1.5.1 Removal of Old Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
1.5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
1.5.3 Preparation of new Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
1.5.4 Fitting new Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22

3UHVVXUH7HVW
1.0.0 Pressure Testing Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25

O-VSP-36TOC.fm 1-3
7DEOHRI&RQWHQWV

&KHPLFDO'RVLQJRI6FDOH&RQWURO&KHPLFDOV
1.0.0 Prevention of Scaling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
1.1.0 Feed Water Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
1.2.0 Chemical Dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
1.2.1 Scale Inhibitor Dosage Equipment for Feed Water . . . . . . . . . . . . . . . . . . page 28
1.2.2 Safety Precautions with the use of Chemicals . . . . . . . . . . . . . . . . . . . . . . page 29

7URXEOH6KRRWLQJ
1.0.0 Test Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31
1.1.0 Trouble Shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31

0DLQWHQDQFHRI)UHVKZDWHU3XPS
1.0.0 Maintenance of Freshwater Pump Types PVVF 1525-1532-2040 . . . . . . . page 35
1.1.0 Overhaul of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35
1.1.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36
1.1.2 Dismantling Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36

0DLQWHQDQFHRI(MHFWRU3XPS
1.0.0 Maintenance of Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
1.1.0 Overhaul of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
1.1.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40
1.1.2 Dismantling Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42

6DOLQRPHWHU
1.0.0 Salinometer Type DS-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
1.1.0 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
1.2.0 Installation (for DS-20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
1.3.0 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
1.3.1 Testing the Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
1.3.2 Adjustment of Alarm Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
1.3.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45

6SDUH3DUWV
1.0.0 Ordering Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47
1.1.0 Alfa Laval Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47

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1-4 O-VSP-36TOC.fm
 6DIHW\,QVWUXFWLRQVDQG:DUQLQJV

Should you need further clarification regarding this manual, do not hesitate to con-
tact your local Alfa Laval representative - or call Alfa Laval Desalt directly.

7HOHSKRQH +45 (for Denmark) 39 53 60 00

7HOHID[ +45 (for Denmark) 39 53 65 66

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The following symbols in this manual point out safety precautions. It means your at-
tention is needed and your safety is involved.

:$51,1*

This symbol is used to indicate the presence of a hazard which can or will
cause severe personal injury, if the warning is ignored.

&$87,21

Certain passages of the text will be marked with a caution mark. This mark
indicates the presence of hazard which will or can cause property damage
if the instructions are not observed.

127(

This type of instruction indicates a situation which, if not avoided, could re-
sult in damage to the equipment.

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:$51,1*

The freshwater generator is not to be operated in polluted water or within

20 miles from the coast

Freshwater must not be produced from polluted water, as the produced water can
be unsuitable for human consumption.

If manuals are translated to local language the unit comply with the EEC Machinery
Directive and EN 292-1/2 standards. For EEC land installations manuals MUST be
available in local language before installing and operating the unit.

The unit also comply with EN 50081-2 and EN 50082-2 “Industry” with regards to the
EMC directive from EEC.

:$51,1*

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• Use ear protection in noisy environments.

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• Use correct lifting tools.
• Do not work under hanging load.

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• Wear gloves to avoid burns by hot surfaces.

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• Wear gloves to avoid cuts by sharp edges when handling machined
parts.
• Wear helmet to avoid cuts by sharp edges during maintenance of the
equipment.

127(

• Max. ambient temperature for the equipment is 50°C (122°F).

• Min. ambient temperature for the equipment is 0°C (32°F).

1-6 Samare04.fm
 6\VWHP'HVFULSWLRQ

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The generator consists of the following components:

1. 7KHVHSDUDWRUYHVVHO
separates the produced vapour from the brine.

2. 7KHHYDSRUDWRUVHFWLRQ
(heating section) Consists of a plate heat exchanger and is enclosed in lower
part of the separator vessel.

3. 7KHFRQGHQVHUVHFWLRQ
(cooling section) also consists of a plate heat exchanger placed in the upper
part of the separator vessel.

SyVSP-36.fm 1-7
6\VWHP'HVFULSWLRQ

4. 7KHFRPELQHGEULQHDLUHMHFWRU
extracts incondensable gases from the separator vessel and the evaporator
vessel and the evaporator vessel, and brine from the separator vessel.

5. 7KHHMHFWRUSXPS
is a combined cooling/feed/ejector water pump. The pump supplies sea water
for the condenser, jet water for the combined brine/air ejector and feed water
for evaporation.

6. 7KHIUHVKZDWHUSXPS
extracts the produced water form the condenser and transfers it to the fresh-
water tank.

7. 7KHVDOLQRPHWHU
continuously checks the salinity of the produced water. The alarm setpoint is
adjustable.

8. 7KHFRQWUROSDQHO
contains starters for the electric motors, control equipment and salinometer.
The control panel is prepared for remote start/stop of all motors.

9. 7KHFRQGHQVDWHSXPS
extracts condensate from the evaporator section.

10. 7KHVWHDPUHJXODWLQJHTXLSPHQW
for regulating the temperature of the hot water loop and pressure conditions of

1-8 SyVSP-36.fm
 6\VWHP'HVFULSWLRQ

heating steam entering the heat exchanger. This includes a thermostatically

controlled safety shut.off function (maximum inlet temperature 100°C)

11. 7KHGHVXSHUKHDWLQJXQLW
brings down the temperature of the pressure reduced steam to a steam temper-
ature of 4-5°C above the saturation temperature in order to eliminate the risk of
wet steam.

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The combined brine/air ejector driven by the combined cooling/ejector water pump
creates a vacuum in the system in order to lower the evaporation temperature of the
feedwater.

The feedwater is introduced into the evaporator section through an orifice, and is dis-
tributed itself into every second plate channel (evaporation channels).

The hot water is distributed itself into the remaining channels, thus transferring its
heat to the feedwater in the evaporation channels.

Having reached boiling temperature - which is lower than at atmospheric pressure -

the feed water undergoes a partial evaporation, and the mixture of generated vapour
and brine enters the separator vessel, where the brine is separated from the vapour
and extracted by the combined brine/air ejector.

after passing a demister the vapour enters every second plate channel in the con-
denser section.

'386:&
The sea water supplied by the combined cooling/ejector water pump distributes
itself into the remaining channels of the condenser section, thus absorbing the
heat being transferred from the condensing vapour.

'38&&
For the condensate cooled freshwater generator the sea water in the condenser
is replaced by condensate from the ship’s turbine system.

The produced freshwater is extracted by the freshwater pump and led to the fresh-
water tank.

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On the delivery side the freshwater pump an electrode unit is fitted. Together with the
salinometer this unit continuously checks the salt content of the produced freshwater.
In case of too high salinity, the produced water is dumped to the bilge.

The slat content of the water is so low that it meets all common requirements to boiler
feed water. If there are no special requirements form the authorities, it can be used
directly as drinking water.

SyVSP-36.fm 1-9
6\VWHP'HVFULSWLRQ

:$51,1*

The freshwater distiller is not to be operated in polluted water or within 20

miles from the coast.

Freshwater must not be produced from polluted water, as the produced water can
be unsuitable for human consumption.

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The steam valve VA-SS-02 is a combined steam pressure regulating and safety cut
off valve.

The steam pressure is regulated during operation by means of a controller mounted

in the control panel. The controller gets the input signal from the temperature trans-
mitter TT-SS-02 converting the actual steam temperature to an electric input signal
4-20 mA.

The output signal from the controller is given to an electric-pneumatic positioner on

the combined steam pressure regulating and safety cut off valve.

The electric pneumatic positioner regulate the air to the actuator which equipped
with a spring return close.

The actuator will close the valve in case:

1. Air failure in operating airsystem.

2. Too high steam temperature detected by temp. transmitter TT-SS-02. In case

of malfunction of the desuperheating system, or because of too high steam in-
let temperature from the steam supply system.

3. Low vacuum.

4. Low feedwater pressure.

5. Electric power supply failure.

6. Malfunction of the desuperheating system. (too high steam temperature acc.

to set point of the controller causing re. valve VA-CO-02 fully opened)

1-10 SyVSP-36.fm
 6\VWHP'HVFULSWLRQ

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The desuperheating system secure saturated steam conditions in the steam before
it enters the heat exchanger.

The amount of water injected in the steam requited during operation by the flow reg-
ulating valve VA-CO-02, getting the input from a controller mounted in the control
panel.

This controller gets the signal from the temperature transmitter TT-SS-02 converting
the actual team temperature to an electric input signal 4-20 mA.

The solenoid valve VA-CO-01 is controlled by the same control circuit mentioned in
sect. 1.3.1 item 2, 3, 4, 5 and 6.

If the valve VA-CO-02 is fully open for more than 10 minutes, a limit switch will close
for air inlet and condensate inlet.

 6ROHQRLG9DOYHV
Solenoid valves VA-FR-02 and VA-FR-05 are controlled by the salinometer in the
control panel. During normal operation valve VA-FR-02 is open and VA-FR-05 is
closed. In case of high salinity the valve position will change.

 6HW3RLQWIRU2SHUDWLQJ6\VWHP

Flow indicator FI-FT-01: in acc. with manufacturer recom-

mendation of feed water anti scaling
chemicals.
Desuperheating system regulating max. 95°C.
controller: (in control panel)

SyVSP-36.fm 1-11
6\VWHP'HVFULSWLRQ

 6HW3RLQWIRU$ODUP6\VWHP

Desuperheating system regulating 110°C.

controller: (in control panel)
Timer relay 5K2: (in control panel) 10 min.
Pressure switch PT-ES-01: 300 KPa g.
Vacuum switch PT-EI-01: 30 KPa abs.
Salinometer: 1,5 ppm
Thermal relay for freshwater pump: 1,6 A
Thermal relay for ejector pump: 37 A

1-12 SyVSP-36.fm
 Operating Instructions

WARNING
DO NOT operate the plant in polluted water.

Freshwater must not be produced from polluted water, as the produced water will be
unsuitable for human consumption.

1.0.0 Starting and Stopping Procedure

CAUTION

Before starting up please observe instructions for feedwater treatment, see

“Chemical dosing of scale control chemicals”.

Please refer to P1-diagram (see “FWG Order Specification”).

1.1.0 Starting

1. Open valves on the suction and discharge side of the ejector pump.

2. Open overboard valve for combined brine/air ejector.

3. Close air screw VA-El -01 on the separator.

4. Start ejector pump to create a vacuum of mm. 90%.

Pressure at combined brine/air ejector inlet minimum 300 KPa .

Back pressure at combined brine/air ejector outlet maximum 60 KPa.

For D-PU-36-125 CC only:

5. Open condensate inlet and outlet valves.

6. Start condensate supply to condenser by adjusting by-bass valve step wise, in-
let the desired condensate flow is reached.

OpVSP-36.fm 1-13
Operating Instructions

1.1.1 Evaporation

When there is a minimum of 90% vacuum (after maximum 10 minutes).

7. Open valve for feed water treatment VA-FT-01.

8. Secure that the air inlet for steam pressure regulating valve VA-SS-02 and
desuperheating flow regulating valve VA-CO-02 is open (500-700 KPa).

9. Secure that the condensate inlet for de superheating is open (maximum 1.3
MPa).

10. Open the valve for condensate outlet to main condenser.

11. Open the main steam shut-off valve.

12. Set the operating mode for desuperheating on the temperature controller to the
MANUAL , then open the flow regulating valve VA-CO-02 (40~50％) by using
two arrow buttons on the temperature controller .

The valve opening value(％) is displayed in display window of the controller

when the operating mode is manual, then the valve opening value can be
adjusted manually by using two arrow buttons.

13. Make sure that the set point of steam pressure on the steam pressure
controller is “0”.

Set the operating mode on the steam pressure controller to the AUTO , then
open the steam pressure regulating valve VA-SS-02 gradually(5-10 KPa/min. )
by adjusting the steam pressure set point on the steam pressure controller
until the specified steam pressure is reached(maximum 75 KPa A).

14. Start condensate pump immediately when the indication lamp for “Steam
Valve Open” is lit up during above step 13.

● The condensate pump can not be started before the indication lamp for
“Steam Valve Open” is lit up.

15. Change the operating mode for desuperheating on the temperature controller
to AUTO when steam temperature is reached to 85℃ during above step 13.

CAUTION
The temperature setpoint for desuperheating should be higher(2~3 ℃)
than saturated temperature at current heating steam pressure.

1-14 OpVSP-36.fm
 Operating Instructions

* Reference table
Pressure Saturated temperature Temperature setpoint for desuperheating
(Recommended)
0.75 KPa A 92.0 ℃ 94 ℃
0.70 KPa A 90.0 ℃ 92 ℃
0.65 KPa A 88.0 ℃ 90 ℃
0.60 KPa A 85.9 ℃ 88 ℃

1.1.2 Condensation

After approx. 3 minutes the boiling temperature will drop again, and normal vacuum
is reestablished.

18. Open valve to freshwater tank.

19. Start freshwater pump.

NOTE
The freshwater pump pressure must be between 120 and 160 KPa (1.2-
1 .6 kp/cm2).

After starting the freshwater pump the flow sight glass in the air suction pipe must
be empty.

CAUTION
If water remains in the flow sight glass, please refer to “Trouble shooting”.

1.2.0 Adjustment of Sea Cooling Water

The sea cooling water flow is correct, when the pressure at the inlet of the combined
air/brine ejector is between 300 and 400 KPa (3.0 -4.0 kp/cm2 ).

OpVSP-36.fm 1-15
Operating Instructions

1.3.0 Stopping the Plant

1. Close the steam pressure regulating valve VA-SS-02 by adjusting the set point
for the steam pressure controller in control panel slowly (step-wise) to 0％.

● The condensate and fresh water pumps are automatically stopped .

2. Close valve for air inlet.

3. Close the main steam shut-off valve.

4. Close valve for condensate for desuperheating inlet.

5. Close valve for feedwater treatment VA-FT-01.

6. Keep ejector pump running until the distiller unit is cooled down.
* If cooling down is performed correctly, the surface temperature at evaporator
section(lower frame surface) will be below 40 ℃.

7. Stop the ejector pump.

8. Open air screw VA-El-Ol to release a vacuum.

9. Close valves on the suction and discharge side of the ejector pump.

10. Close overboard valve for combined brine/air ejector.

11. Close the valve to freshwater tank.

CAUTION
All valves must be shut, while the distiller is out of operation. Except air
screw

1.4.0 Long Term Standstill

If the distiller is out of operation for a period longer than 14 days, please observe
“Maintenance of separator vessel”.

OpVSP-36.fm 1-16
 0DLQWHQDQFH

 :K\\RXQHHGWRSHUIRUPUHJXODUPDLQWHQDQFHGXWLHV
Regular maintenance of the plant will improve performance and availability.

The maintenance schedule on the following pages will tell you how often service
should be performed on the main components.

As the actual operating conditions of the plant are of major influence on the life time,
the overhaul dates are not obligatory but only recommended intervals.

When the plant has been in operation for a longer period of time and experience has
been established as to the actual performance, it will be possible to adapt the main-
tenance schedule.

For service on minor components please refer to component instructions.

 2YHUKDXO,QWHUYDOV

&RPSRQHQW 2SHUDWLQJ $FWLRQ

+RXUV

Evaporator section As required Clean in inhibited acid bath

Condenser section As required Clean with pure freshwater and

brush

Combined ejector/cooling 8000 h Measure seal ring and impeller.

water pump with motor Examine mechanical shaft seal,
cooling water pipe passage.
Megger-test electric motor.
Clean pump thoroughly before
reassembly.

Freshwater extraction 8000 h See above

pump with motor

Combined air/brine ejector 8000 h Measure nozzles and diffuser

and compare to measurements
in technical specification.

MV-valves 4000 h Disassembly and inspect for

damage.

Demister 8000 h Clean in inhibited acid bath

Madpue01.fm 1-17
0DLQWHQDQFH

&RPSRQHQW 2SHUDWLQJ $FWLRQ

+RXUV

Manometers 8000 h Adjust with control manometer

Salinometer See separate in- See separate instructions

structions

 0DLQWHQDQFHRI6HSDUDWRU9HVVHO
The separator vessels and the pressure plates for the heat exchanger sections
(evaporator and condenser) are made of stainless steel with a special chemical
treatment. This treatment will reestablish normal surface oxidation after work- up at
the factory. The preparation is a natural protection of the stainless steel.

&$87,21

To preserve this natural protection DO NOT scrape or scratch the inside

surface of the separator vessels.

Further, there are isolating layers on the separator inside walls, where the heat ex-
changer sections are mounted.

Whenever the sections are dismantled, these isolating layers must be checked for
defects. Repair any defects according to the maintenance guide for glass flake coat-
ing.

Whenever the separator vessel is opened,

• check that the anodes are functioning

If the anodes are not functioning and/or worn, replace them.

127(

If the unit is stopped for a longer period than 14 days.

• Open separator covers and clean unit inside with freshwater.

• Let the unit dry out completely, before closing covers.

1-18 Madpue01.fm
 0DLQWHQDQFH

 0DLQWHQDQFHRI(YDSRUDWRU6HFWLRQ
Clean evaporator as follows:

1. Remove bolts in front cover, and open.

2. Loosen the 6 nuts in plate stack gradually, so that no nut is carrying the entire
load alone

3. Remove plate stack.

127(

If some of the gaskets come loose on removing plate stack, please see
section 1.5.2

4. Submerge plates completely in a hot, inhibited acid bath at maximum 50ºC. For
further instructions see “Chemical dosing of scale control chemicals”.

:$51,1*

Always follow carefully the suppliers instructions when using inhibited ac-
ids.

Remember to neutralize according to suppliers instructions.

5. Examine plates and gaskets for possible damage, and remove damaged plates
and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate together with one of the adjacent
plates.

127(

The assembly measurements must be reduced with 5.4 mm per plate, if

plates are removed from plate stack.

Madpue01.fm 1-19
0DLQWHQDQFH

&$87,21

The ES and EE plate cannot be removed but must always be replaced, with
a corresponding plate.

7. Reassemble evaporator section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test evaporator section before closing front cover.

7KHHYDSRUDWRUVHFWLRQLVSUHVVXUHWHVWHGE\OHWWLQJKRWZDWHUFLUFXODWHWKURXJK
WKHVHFWLRQZLWKE\SDVVYDOYHIRUKRWZDWHULQQRUPDOUXQQLQJSRVLWLRQ

10. When the evaporator section is found to be tight, close front cover and tighten
bolts.

11. Retighten, when vacuum has been reestablished.

 0DLQWHQDQFHRI&RQGHQVHU6HFWLRQ
Clean condenser as follows:

1. Remove bolts in front cover, and open.

2. Loosen the 6 nuts in plate stack gradually, so that no nut is carrying the entire
load alone.

3. Remove plate stack.

127(

If some of the gaskets come loose on removing plate stack, please see
section 1.5.2

4. Scrub plates with a soft brush and plain hot water at maximum 50°C.

5. Examine plates and gaskets for possible damage, and remove damaged
plates and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate and one of the adjacent plates.

1-20 Madpue01.fm
 0DLQWHQDQFH

127(

The assembly measurements must be reduced with 5.4 mm per plate, if

plates are removed from plate stack.

&$87,21

The ES and EE plate cannot be removed, but must always be replaced,

with a corresponding plate.

7. Reassemble condenser section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test condenser section before closing front cover.

7KHFRQGHQVHUVHFWLRQLVSUHVVXUHWHVWHGE\OHWWLQJVHDZDWHUIURPWKHFRP
ELQHGFRROLQJZDWHUHMHFWRUSXPSFLUFXODWHWKURXJKWKHVHFWLRQ

&$87,21

Before starting the combined ejector/cooling water pump, the feed water
must be sealed off.

10. When the condenser section is found to be tight, close front cover and tighten
bolts.

11. Retighten, when vacuum has been reestablished.

 5HQHZDORI3ODWH+HDW([FKDQJHU*DVNHWV

 5HPRYDORI2OG*DVNHWV
Pull the old gaskets out of groove.

If the gasket cannot come off directly, heat the back of the gasket groove with a
hot-air blower or butane gas burner.

Madpue01.f 1-21
0DLQWHQDQFH

Pay attention not to overheat the plates.

You will obtain a suitable temperature, if the flame is held 10 to 15 cm behind the
plate.

:$51,1*

DO NOT use DFHW\OHQHJDV

 &OHDQLQJ
Charred or loose glue and rubber remains must be removed, e.g. using a rotating
stainless steel brush. The width should be adapted (Ø40-50 mm, width 8-10 mm).
Thin layers of glue which are difficult to remove, may remain.

Clean the gasket groove with a clean cloth, dipped in a solvent (acetone, methyl eth-
yl ketone, trichlorethylene etc.).

:$51,1*

Be careful when handling these solvents, as they may be hazardous to

your health. Observe suppliers’ instructions.

*DVNHWVWKDWKDYHORRVHQHGcDQEHJOXHGRQ&OHDQJDVNHWJURRYHFDUHIXOO\ZLWKD
VKDUSWRRO7KHQFOHDQWKHORRVHSDUWRIWKHJDVNHWZLWKHPHU\FORWKRUVDQGSDSHU
)LQDOO\FOHDQJURRYHDQGJDVNHWZLWKDVROYHQWDQGJOXH

 3UHSDUDWLRQRIQHZ*DVNHWV
Dry new gaskets with a clean cloth that has been slightly moistened with a solvent.

 )LWWLQJQHZ*DVNHWV
1. Apply a thin layer of glue to both gasket and groove.

2. Let the glue dry for 10-15 minutes.

3. Fit new gasket into groove.

*DVNHWVPD\VRPHWLPHVEHVOLJKWO\VKRUWRUORQJ

1-22 Madpue01.fm
 0DLQWHQDQFH

6KRUWJDVNHWVVKRXOGEHVWUHWFKHGEHIRUHEHLQJILWWHGLQWRWKHJURRYH

/RQJJDVNHWVVKRXOGEHILWWHGLQWRWKHJURRYHVDWWKHSODWHHQGVILUVWDQGWKHQ
JUDGXDOO\EHSXVKHGLQWRWKHJURRYHWRZDUGVWKHPLGGOH

,IQHFHVVDU\WDSHJDVNHWLQWRJURRYH

Madpue01.fm 1-23
0DLQWHQDQFH

1-24 Madpue01.fm
 3UHVVXUH7HVW

 3UHVVXUH7HVWLQJ6HSDUDWRU
If there are leaks in the system, it will be necessary to carry out a pressure test in
order to identify the leak:

1. Close valve on discharge side of combined cooling water/ejector pump.

2. Close discharge valve on overboard line from combined brine/air ejector.

3. Close valve on discharge line to freshwater tanks.

4. Open separator vessel in order to vent the vessel, when supplying water for
pressure test.

5. Supply water (sea or freshwater) at the socket for the connection of feed water
treatment.

&$87,21

Maximum pressure on the separator vessel is 150 KPa (1.5 kp/cm²) (21
PSI).

Prdpue00.fm 1-25
3UHVVXUH7HVW

1-26 Prdpue00.fm
 &KHPLFDO'RVLQJRI6FDOH&RQWURO&KHPLFDOV

 3UHYHQWLRQRI6FDOLQJ
During the evaporation of sea water there is always a risk of scaling on the heating
surfaces. This will lead to a reduction of the K-values of the heating surface and de-
creasing freshwater production and reduction of plant efficiency.

In order to effectively prevent scaling the operators must be aware of the factors in-
fluencing the scale formation.

 )HHG:DWHU5DWLR
The feedwater ratio is an extremely important factor. It is defined by the relationship
between the feedwater amount fed into the plant and the produced amount of fresh-
water.

If the feedwater ratio is reduced, the concentration will rise in the plant subsequently
resulting in scale formations.

Two things may shift the feedwater ratio: first of all direct adjustment of the feedwater
system, and secondly exceeding the maximum freshwater production laid out for the
plant. The operators must observe the following rules at all times.

&$87,21

DO NOT adjust feedwater system. Feedwater pressure min. 300 max. 400
KPa g.

 &KHPLFDO'RVDJH
In order to control scale formations on the heating surfaces and continuously ensure
long operation periods without acid cleaning the plant, it is absolutely necessary to
dose scale control additives to the feedwater. The operators must follow the instruc-
tions for chemical dosing given by the chemical supplier carefully.

Cdgnpe00.fm 1-27
&KHPLFDO'RVLQJRI6FDOH&RQWURO&KHPLFDOV

&$87,21

If the distiller is operated at boiling temperatures above 45°C without chem-

icals, frequent cleaning of the evaporator will be necessary.

We recommend that you do not operate the freshwater distiller without rec-
ommended chemical dosage at boiling temperatures above 45°C. Even at
lower temperatures it can be recommended.

 6FDOH,QKLELWRU'RVDJH(TXLSPHQWIRU)HHG:DWHU
Please refer to drawing, see “FWG Order Specification”.

• When adding chemicals mix thoroughly to ensure a homogenous blend of

chemicals and water.

Use a fully soluble scale inhibitor, e.g. on polymer basis. The following products can
be recommended:

NALFLEET Evaporator treatment 9-913

AMEROYAL EVAPORATOR TREATMENT

HEXAMETHAPHOSPHATE

1. Mix the required quantity for 24 hours operation in the tank according to mak-
er’s instructions.

2. Adjust flowmeter to cover the maximum freshwater output from the distiller.

3. Flush the dosage system regularly.

1-28 Cdgnpe00.fm
 &KHPLFDO'RVLQJRI6FDOH&RQWURO&KHPLFDOV

 6DIHW\3UHFDXWLRQVZLWKWKHXVHRI&KHPLFDOV

:$51,1*

1 USE eye protection and gloves. Avoid direct skin contact, eye contact
or contact with clothes.

2 CLEAN empty containers before disposal.

3 If chemicals are spilled on clothes, rinse with water and dispose off
clothes.

4 If chemicals are spilled on the floor, rinse with water and suck remain-
ing chemicals off with sand. Clean the spot immediately afterwards.

5 Scale inhibitor is hazardous, if consumed in a concentrated solution.

If consumed by mistake.
,00(',$7(/<6((.0(',&$/$77(17,21

6 If eyes get in contact with the chemicals, rinse for at least 20 minutes.
,00(',$7(/<6((.0(',&$/$77(17,21

Cdgnpe00.fm 1-29
&KHPLFDO'RVLQJRI6FDOH&RQWURO&KHPLFDOV

1-30 Cdgnpe00.fm
 7URXEOH6KRRWLQJ

 7HVW6KHHW
Before taking any action, please fill in a test sheet to find possible causes of malfunc-
tions.

Test sheets can be found in the back of this binder.

 7URXEOH6KRRWLQJ7DEOH

3UREOHP &DXVH $FWLRQ

Drop in production. Partially blocked feed water Dismantle evaporator section,

orifice and/or sludge deposits and clean evaporator and ori-
on hot water side. fice.

Sludge on the heat exchanger Dismantle condenser section,

plates on the sea water side. and clean.

Inlet channel in evaporator/ Dismantle evaporator/ con-

condenser plate stack denser section, and clean.
blocked, e.g. with rust scales,
gasket fragments etc.

Too low ejector pump pres- See instructions for “Low Sea
sure. Cooling water/Ejector pump
flow / pressure”, below.

Leakages Carry out a pressure test at

max. 150 KPa (1.5 kp/cm²)
(21.8 PSI).a

Foreign bodies in ejector noz- Inspect nozzles, and clean.

zles. Replace nozzles, if damaged.

Too high back pressure on Check overboard pipe and

ejector outlet side. Max 60 valves for blocking / function-
KPa (0.6 kp/cm²) (8.7 PSI). ability.

Non-return valve in air extrac- Replace non-return valve.

tion pipe defect.

Hot water temperature too Reduce to specified tempera-

high. ture.

Defective water clock. Examine water clock. Let the

produced water flow through
water clock into a 10 l pail, and
check production with a stop
watch.

Trw26e03.fm 1-31
7URXEOH6KRRWLQJ

3UREOHP &DXVH $FWLRQ

Low Sea Cooling water/Ejector Too low ejector pump pres- Clean, or replace pressure
pump flow / pressure. sure. gauge.
Minimum pressure 300 KPa
(3.0 kp/cm²) (43.5 PSI). Suction strainer blocked. Clean suction strainer.
At inlet side of ejector.
Valves on suction or pressure Examine and overhaul defec-
pipe defect. tive valves.

Leakage from suction pipe to Repair.

pump.

Impeller / seal ring defective. Check pump maximum clear-

ance See “Maintenance of
Ejector Pump”

Clocked up condenser plate Dismantle condenser plate

stack. stack and clean.

Pump rotating in wrong direc- Interchange phases.

tion.

Sight glass overflow. Normal Suction pipe leakage. Check suction pipe especially
back pressure for freshwater unions and connections. Re-
pump is 120 - 160 KPa (1.2 - pair.
1.6 kp/cm²) (17.4 - 23.2 PSI).
Except for JWP-16-C40 gener- Mechanical seal in freshwater Replace mechanical seal.
ator type, where the max. back pump defect.
pressure is 80 KPa (0.8 kp/cm²)
(11.6 PSI). Impeller / seal ring in freshwa- Check pump maximum clear-
ter extraction pipe defect. ance See “Maintenance of
Freshwater Pump”

Pump rotating in wrong direc- Interchange phases.

tion.

Valves to freshwater tank Check all valves.

closed.

Inlet filter for water clock Clean filter.

blocked.

Salinity too high (more than 2.0 Demister not fitted correctly. Check that demister is fitted
ppm). against baffle and front cover.

Front cover gasket defect or Replace front cover gasket.

not fitted correctly.

Insufficient brine extraction. See separate instructions for

insufficient brine extraction,
below.

Electrode unit defective or Examine electrode unit for

dirty. cracks. Check that it is fitted
correctly. Clean, if necessary.

1-32 Trw26e03.fm
 7URXEOH6KRRWLQJ

3UREOHP &DXVH $FWLRQ

Leakage in condenser sec- Open distiller and pressure test

tion. condenser. Max. 600 KPa (6.0
kp/cm²) (87 PSI). If there is a
defective plate, remove togeth-
er with adjacent plate assem-
ble plate stack according to
new plate number with re-
duced assembly measure-
ments. Check plate gaskets
and replace, if necessary.

Insufficient brine extraction - Ejector pump pressure too See special instructions for
brine level in sight glass higher low. “Low Sea Cooling water/Ejec-
than 20 mm. tor pump flow / pressure”,
above.

Foreign bodies in ejector noz- Check nozzles, and clean. Re-

zles. place damaged nozzles.

Too high back pressure down- Examine overboard pipe and

stream of ejector. valves.

Wrong dimension of feedwa- Examine orifice dimension -

ter orifice. check technical specification.

Non-return valve in brine suc- Examine valve and repair, or

tion pipe of ejector defect. replace.

Frequent refill of freshwater Leakage in evaporator sec- Open distiller and pressure test
expansion tank due to loss of tion. condenser. Max. 600 KPa (6.0
hot water. kp/cm²) (87 PSI).
If there is a defective plate, re-
move together with adjacent
plates assemble plate stack
according to new plate number
with reduced assembly mea-
surements. Check plate gas-
kets and replace, if necessary.

Abnormal amperage con- Ejector nozzles defective. Replace nozzles.

sumption of ejector pump mo-
tor. Wrong dimension of feedwa- Check dimensions on spare
ter inlet orifice. parts list, See List of spare part
drawings”, and replace if nec-
essary.

Bearings in motor defective. Examine with stetoscope, and

replace bearings, if defective.

Contactor defective. Examine and replace contactor

set, if defective.

Breaking of phases. Max. 5% difference in amper-

age between phases.

Trw26e03.fm 1-33
7URXEOH6KRRWLQJ

1-34 Trw26e03.fm
 0DLQWHQDQFHRI)UHVKZDWHU3XPS

 0DLQWHQDQFHRI)UHVKZDWHU3XPS7\SHV399)
The following instructions must be carefully observed whenever it becomes neces-
sary to overhaul or repair the freshwater pump.

Please refer to drawing for item references in the text.

 2YHUKDXORIWKH3XPS
1. Remove the QXWV on the SXPSFDVLQJ

2. Lift motor with SXPSFRYHU and LPSHOOHU clear of SXPSFDVLQJ.

3. Unscrew FRXQWHUVXQNVFUHZ (right hand thread).

4. Remove impeller. Normally, it can be removed without using dismantling tools.

5. Remove NH\

6. Remove the PHFKDQLFDOVKDIWVHDO

7. Inspect the ceramic ring, the carbon ring and the spring.

8. Replace mechanical shaft seal, if necessary. It is recommended to grease the

shaft and seat for the ceramic ring with glycerine in order to make it easier to
assemble the mechanical shaft seal. Please also observe separate instruc-
tions for mechanical shaft seal delivered together with the seal.

Mapvfe00.fm 1-35
0DLQWHQDQFHRI)UHVKZDWHU3XPS

9. Fit carbon ring, spring and spring holder on pump shaft.

10. Inspect impeller and the drilled sealing water channel for clogging, and clean.
 5HPHPEHUWRUHSODFHJDVNHW

12. Reassemble in reverse order.

 &OHDUDQFH
In connection with the inspection be sure to measure the LPSHOOHUDQGZHDUULQJ
in order to secure that the clearance is no more than 0.5 mm on the diameter.

&$87,21

The SXPSVKDIW must only be dismantled, if pump shaft or electric mo-

tor bearing has to be replaced.

In this case carefully observe “Dismantling pump shaft”.

 'LVPDQWOLQJ3XPS6KDIW
1. Dismantle the pump as described above.

2. Unscrew SRLQWHGVFUHZV

3. Carefully insert two screw drivers behind the pump shaft, and loosen it.

,IWKHSXPSVKDIWGRHVQRWFRPHORRVHXVHWKHVSHFLDOGLVPDQWOLQJWRROVVKRZQ
EHORZ

7KHWRROLVQRW$OID/DYDO'HVDOWVXSSO\

1-36 Mapvfe00.fm
 0DLQWHQDQFHRI)UHVKZDWHU3XPS

The tool consists of a pipe (A), a disc (B) with hole for the screw (C) and a nut
(D), washer (E).

3OHDVHQRWHWKDWWKHOHQJWK/PXVWEHORQJHUWKDQWKHOHQJWKO

Place pipe around the shaft. Fasten the screw with nut and washer into the
threaded hole (M12) on the shaft end.

Loosen shaft by tightening the nut while holding on to the screw.

&$87,21

DO NOT grind the motor shaft.

4. Mount the new pump shaft on the motor shaft.

5. Make sure that the pump shaft fits the motor shaft without any obstructions, be-
fore final shaft fitting as follows:

• Tap onto the end of the pump shaft slightly with a RUBBER hammer.

6. Tighten SRLQWHGVFUHZV as follows:

Mapvfe00.fm 1-37
0DLQWHQDQFHRI)UHVKZDWHU3XPS

127(

The torque should be 5 Nm (0.5 kpm) and the maximum wobble 60µm.

7. Check the wobble of the pump shaft with a dial indicator.

8. Assemble the pump as described above.

1-38 Mapvfe00.fm
 0DLQWHQDQFHRI(MHFWRU3XPS

 0DLQWHQDQFHRI(MHFWRU3XPS
,IVXSSOLHGIURP$OID/DYDO

The following instructions must be carefully observed whenever it becomes neces-

sary to overhaul or repair the above mentioned pump. Please refer to drawing for
item references in the text.

 2YHUKDXORIWKH3XPS
1. Remove the VHWVFUHZV in SXPSFRYHU

0RWRUZLWKPRWRUEUDFNHWSXPSFRYHUDQGLPSHOOHUFDQQRZEHOLIWHG
FOHDURIWKHSXPSFDVLQJ

2. Unscrew the VFUHZ (right-hand thread).

3. Remove impeller.

Macnle00.fm 1-39
0DLQWHQDQFHRI(MHFWRU3XPS

127(

Normally, the impeller can be removed without using dismantling tools.

If not, you can fit dismantling screws into the two threaded holes in the im-
peller.

4. Remove the key 26 and the mechanical seal 8 (including spring holder, spring
and carbon ring).

5. Inspect the ceramic ring, the carbon ring and the spring. Replace, if necessary

,IPHFKDQLFDOVHDOKDVWREHUHSODFHGSURFHHGDVIROORZV

‡ 8QVFUHZVHWVFUHZWRUHPRYHSXPSFRYHUIURPPRWRUEUDFNHW
LQRUGHUWRJDLQDFFHVVWRFHUDPLFULQJ

,QRUGHUWRPDNHLWHDVLHUWRDVVHPEOHWKHPHFKDQLFDOVHDOWKHVKDIWDQGULQJ
VHDWPD\EHJUHDVHGZLWKJO\FHULQH3OHDVHDOVRUHIHUWRVHSDUDWHLQVWUXFWLRQV
IRUPHFKDQLFDOVHDOGHOLYHUHGWRJHWKHUZLWKWKHVHDO

‡ $IWHUILWWLQJWKHFHUDPLFULQJILWSXPSFRYHUWRPRWRUEUDFNHW

‡ )LWFDUERQULQJVSULQJDQGVSULQJKROGHU

6. Clean drilled cooling water channel in SXPSFRYHU

7. Inspect impeller and threaded holes for clogging.

8. 5HPHPEHUWRFKDQJHWKH2ULQJ

9. Reassemble in reverse order.

 &OHDUDQFH
In connection with the inspection, the LPSHOOHUand ZHDUULQJV are measured
in order to secure that the clearance is not larger than stated in the diagram below.

1-40 Macnle00.fm
 0DLQWHQDQFHRI(MHFWRU3XPS

:HDUULQJ‘ &OHDUDQFHPD[LPXP &OHDUDQFHPLQLPXP

100 mm 0.5 mm 0.15 mm

150 mm 0.6 mm 0.2 mm

200 mm 0.7 mm 0.25 mm

250 mm 0.8 mm 0.28 mm

300 mm 0.85 mm 0.3 mm

350 mm 0.9 mm 0.3 mm

If the clearance is too big, replace wear rings as follows:

1. Unscrew FRXQWHUVXQNVFUHZV

2. Pull out wear (seal) rings.

3. Fit new wear rings and tighten countersunk screws.

&$87,21

The pump shaft may only be dismantled, if pump shaft or bearings, in the
electric motor have to be replaced.

Carefully observe instructions for “Dismantling pump shaft”.

Macnle00.fm 1-41
0DLQWHQDQFHRI(MHFWRU3XPS

 'LVPDQWOLQJ3XPS6KDIW
If theVKDIW has to be dismantled due to a defect or if electric motor bearing has to
be replaced, proceed as follows:

1. Unscrew SRLQWHGVFUHZV

2. Remove VKDIW. Normally this can be done without using dismantling tools.

&$87,21

DO NOT grind the motor shaft.

3. Fit VKDIW

4. In order to make sure that the coupling is fitted correctly, tap slightly at the shaft
end with a RUBBER hammer.

5. TightenSRLQWHGVFUHZV with a torque of 35 Nm (3.5 kpm).

1-42 Macnle00.fm
 6DOLQRPHWHU

 6DOLQRPHWHU7\SH'6

 7HFKQLFDO6SHFLILFDWLRQ

)XQFWLRQ Measuring (Dot Bar) and supervising salinity of

freshwater produced by seawater desalination.

6XSSO\YROWDJH 90-120 V or 200-240 V AC.

)UHTXHQF\ 50/60 Hz

3RZHUFRQVXPSWLRQ Salinometer 10 VA.

5HOD\FRQWDFWV Max. load 100 VA.

6DOLQLW\GLVSOD\ 0,5 - 20 ppm (Dot Bar).

7HPSHUDWXUHFRUUHFWLRQ Automatic in the range 5 - 85°C.

$ODUPOHYHO Can be set to any value between 0,5 - 20 ppm.

7HVW Can be checked by test switch, 10 ppm.

2XWSXW 4-20 mA Current Loop.

0D[DPELHQWWHPSHUD 55°C.
WXUH
3URWHFWLRQGHJUHH IP 54.

 ,QVWDOODWLRQIRU'6

1. Open front cover.

2. Select correct voltage select according to the main supply voltage 115 V or 230
VAC.

3. Screw salinometer on to bulkhead with six nuts.

4. Connect necessary cables to the terminals.

5. Close front cover.

6. Test salinometer function (see instructions for use).

Salise00.fm 1-43
6DOLQRPHWHU

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1. Switch on mains.

2. Switch on sec. alarm.

Green pilot LED should light up. Dot. Bar displays the measured salinity.

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:$51,1*

The salinometer must be tested at least once a month, and the electrode
unit must be cleaned.

Push TEST switch on.

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1. Switch “MAINS” on.

2. Push sec. alarm off.

3. Adjust Alarm Set to desired alarm level by using the switches.

4. Switch “Sec. Alarm” on.

The salinometer is now ready for use.

If the salinity exceeds the alarm level,

• The two red alarm LEDS flash.

• Solenoid valve is activated.

• Buzzer (if fitted) and external alarm system is activated.

Cancel buzzer and external alarm system by switching “Sec. Alarm” off. Solenoid
valve is not affected.

Switch “Sec. Alarm” on as soon as the salinity is normal again; i.e. when the two red

1-44 Salise00.fm
 6DOLQRPHWHU

LEDS are off.

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&$87,21

Remove electrode unit and inspect/clean after every 1000 hours of opera-
tion. Use a clean and dry rag. Avoid touching the electrodes with the fin-
gers.

Salise00.fm 1-45
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1-46 Salise00.fm
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When ordering spare parts please always state:

1. Serial number.

2. Capacity.

3. Designation.

4. Spare parts drawing number.

5. Position number.

6. Article number.

In order to identify article numbers, please refer to FWG Order Specification and oth-
er drawings.

When ordering parts for pumps proceed as follows:

1. Find article number in the list of drawings.

2. Check spare part drawing and item list with corresponding article number to
identify the item to be ordered.

 $OID/DYDO6HUYLFH
The $OID/DYDOgroup is represented in all major ports of the world.

DO NOT hesitate to contact your $OID/DYDO representative if you have any ques-
tions, problems or require spare parts.

Spmare01.fm 1-47
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$
Adjustment of alarm level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
Alfa Laval service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47
Automatic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10

&
Chemical dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40
Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14

'
Desuperheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
Dismantling pump shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42

(
Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14

)
Feed water ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
Fitting new gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Freshwater Pump Types PVVF 1525-1532-2040 . . . . . . . . . . . . . . . . . . . . . . . . page 35
Freshwater Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9

,
Installation (for DS-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44

/
Long term standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15

0
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45
Maintenance of condenser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
Maintenance of ejector pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
Maintenance of evaporator section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Maintenance of Freshwater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35
Maintenance of freshwater pump types PVVF 1525-1532-2040 . . . . . . . . . . . . . page 35
Maintenance of separator vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18

O-VSP-36IX.fm 1-49
,QGH[
2
Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47
Overhaul intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Overhaul of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39

3
Perform regular maintenance duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Preparation of new gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Pressure testing separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25
Prevention of scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27

5
Removal of old gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Renewal of plate heat exchanger gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21

6
Safety instructions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Safety precautions with the use of chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29
Salinometer type DS-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
Scale inhibitor dosage equipment for feed water . . . . . . . . . . . . . . . . . . . . . . . . page 28
Set Point for Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Set Point for Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
Starting and stopping procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
Steam Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
Stopping the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

7
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
Telefax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Test sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31
Testing the instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
The combined brine-/air ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
The condensate pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
The condenser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
The control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
The de superheating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
The ejector pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
The evaporator section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
The freshwater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
The salinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8

1-50 O-VSP-36IX.fm
 ,QGH[
The separator vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
The steam regulating equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Trouble shooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31

:
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Why you need to perform regular maintenance duties . . . . . . . . . . . . . . . . . . . . page 17
Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9

O-VSP-36IX.fm 1-51
,QGH[

1-52 O-VSP-36IX.fm
COMMANDER 250 User Guide
Universal Process Controller

COMMANDER 250
°C

47.5 °F

OP1

OP2
A1 A2
50.0
R M
Use of Instructions

Warning. Note.
An instruction that draws attention to Clarification of an instruction or
the risk of injury or death. additional information.

Caution. Information.
An instruction that draws attention to Further reference for more detailed
the risk of damage to the product, information or technical details.
process or surroundings.

Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it must be understood that operation of
damaged equipment could, under certain operational conditions, result in degraded
process system performance leading to personal injury or death. Therefore, comply fully
with all Warning and Caution notices.
Information in this manual is intended only to assist our customers in the efficient operation
of our equipment. Use of this manual for any other purpose is specifically prohibited and
its contents are not to be reproduced in full or part without prior approval of Technical
Communications Department, ABB Ltd.

Health and Safety

To ensure that our products are safe and without risk to health, the following points
must be noted:
1. The relevant sections of these instructions must be read carefully before
proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by
suitably trained personnel and in accordance with the information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident
occurring when operating in conditions of high pressure and/or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes
and powders kept dry. Normal safe handling procedures must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any
relevant hazard data sheets (where applicable) may be obtained from the Company
address on the back cover, together with servicing and spares information.
GETTING STARTED
This manual is divided into 5 sections which contain all the information needed to
install, configure, commission and operate the COMMANDER 250. Each section is
identified clearly by a symbol as shown below.

Displays and Function Keys

• Displays and function keys
• LED Indication
• Error Messages

Operator Mode (Level 1)

• Operator menus for:
– Standard controller
– Heat/Cool controller
– Remote Set Point controller
– Profile controller
– Multiple Fixed Set Points controller
• Auto tuning

Set Up Mode (Levels 2, 3 and 4)

8 •
•
•
Level 2 – Tuning
Level 3 – Set Points
Level 4 – Profile

Configuration Mode (Levels 5 and 6)

• Level 5 – Basic hardware and control
functions
• Level 6 – Ranges and passwords

Installation
• Siting
• Mounting
• Electrical connections

Symbol Identification and Section Contents

2-1
CONTENTS
1 DISPLAYS AND FUNCTION KEYS .............................................................2- 3
1.1 Introduction ..........................................................................................2- 3
1.2 LED Alarms and Indicators .................................................................2 -4
1.3 Use of Function Keys ..........................................................................2- 6
1.4 Error Messages ...................................................................................2 7

2 OPERATOR MODE ......................................................................................2- 8

2.1 Introduction ..........................................................................................2- 8
2.2 Standard Controller .............................................................................2- 9
2.3 Heat/Cool Controller .......................................................................... 2-10
2.4 Remote Set Point Controller ............................................................. 2-12
2.5 Profile Controller ............................................................................... 2-14
2.6 Multiple Fixed Set Points Controller ................................................. 2-16
2.7 Auto-tune ........................................................................................... 2-18

3 SET UP MODE ............................................................................................2- 20

3.1 Introduction ........................................................................................2- 20
3.2 Tuning (Level 2) ................................................................................2- 20
3.3 Set Points (Level 3) ...........................................................................2- 24
3.4 Profile (Level 4) .................................................................................2- 27

4 CONFIGURATION MODE ..........................................................................2- 30

4.1 Introduction ....................................................................................2- 30
4.2 Accessing the Configuration Mode ...................................................2- 30
4.3 Basic Hardware and Configuration (Level 5) ...................................2- 32
4.4 Ranges and Passwords (Level 6) .................................................2- 42

5 INSTALLATION ..........................................................................................2- 46
5.1 Siting ..................................................................................................2- 46
5.2 Mounting ............................................................................................2 -48
5.3 Removing the Instrument from the Case ..........................................2- 50
5.4 Electrical Connections ......................................................................2- 51
5.5 Relays, Arc Suppression and Outputs .............................................2- 51

Information.
The fold-out page inside on the back cover of this
manual shows all the frames in the programming
levels. Space is provided on the page for writing the
programmed setting or selection for each frame.

2-2
1 DISPLAYS AND FUNCTION KEYS
1.1 Introduction – Fig. 1.1
The COMMANDER 250 front panel displays, function keys and l.e.d. indicators are
shown in Fig. 1.1.

COMMANDER 250

°C
Units of
measure
Upper Display
8888 °F
indication
(secret-til-lit)

OP1 Lower
Output Value
LEDs
(secret-til-lit) OP2 8888
A1 A2 R M
Display
Manual Control
LED

Alarm LEDs Remote Set Point

LED

Function Keys

Raise

Lower

Auto/Manual

Parameter Advance

Fig. 1.1 Front Panel Displays, Function Keys and Indicators

2-3
 …1 DISPLAYS AND FUNCTION KEYS

1.2 LED Alarms and Indicators – Figs. 1.2 and 1.3

COMMANDER 250

°C

OP1
8888 °F

OP2 8888
A1 A2 R M

A1 M
A2 R

LED Status

All • All LEDs flashing – controller is in the configuration mode.

A1 • Flashes when Alarm 1 is active (off when inactive).

A2 • Flashes when Alarm 2 is active (off when inactive).

R • On when the controller is operating on the remote set point value.

• Off when the controller is operating using the local set point
value or one of the four fixed set points (in multiple set point mode).
• Flashes when a Ramp/Soak profile is running.

M • On when the controller is operating in Manual control mode.

• Off when the controller is operating in Auto control mode.
• Flashes when the controller is performing an auto-tune.

Fig. 1.2 LED Alarms and Indicators

2-4
 1 DISPLAYS AND FUNCTION KEYS…

…1.2 LED Alarms and Indicators – Figs. 1.2 and 1.3

COMMANDER 250

°C °C units of measure

Output 1 LED
OP1
8888 °F
(secret-til-lit)

°F units of measure
(secret-til-lit)
(secret-til-lit)

Output 2 LED
(secret-til-lit)
OP2 8888
A1 A2 R M

LED Status

OPI • LED indicates when the output 1 (heat) value is displayed

in the lower display.

OP2 • LED indicates when the output 2 (cool) value is displayed

in the lower display.

°C • LED indicates when the controller is configured to measure

in degrees Celsius.
°F • LED indicates when the controller is configured to measure
in degrees Fahrenheit.

Fig. 1.3 Secret-til-lit Indicators

2-5
 …1 DISPLAYS AND FUNCTION KEYS

1.3 Use of Function Keys – Fig. 1.4

A – Raise and Lower Keys

bIAS LEV2
50.0 51.0 + tUnE
49.0 –
LEV1
OPEr
Use to change/set a parameter value… and… …move between levels

B – Parameter Advance Key

LEV2 Frame 1
(top of level)
LEVx
tUnE 1001
1002
Press and hold
CYCl Frame 2 1003
5.0
Use to advance to the next frame and… …select the top (LEVEL) frame
within a level… from within a level
Note. This key also stores any changes made in the previous frame

C – Auto/Manual Key

Auto Manual
M M Illuminated

Process Variable
125.2 125.2 Process Variable
Control Set Point 125.8 70 Control Output (%)

Use to select Auto or Manual control mode

Fig. 1.4 Use of Function Keys

2-6
 1 DISPLAYS AND FUNCTION KEYS…

1.4 Error Messages

Display Error/Action To Clear Display

Calibration error Press the key

CAL Turn mains power off and on again
Err (if the error persists contact the
Service Organization).

Configuration error Press the key

CnFG The configuration and/or setup data
Err for the instrument is corrupted.
Turn mains power off and on again Turn mains power off
(if the error persists, check & on again, if the error
configuration/setup settings). persists contact the
Service Organization
A-d A to D Converter Fault
The analog to digital converter is Restore valid input
Err not communicating correctly.

9999 Process Variable Over/Under Select the local set

Range point (rSP.n) in
70 the Operating Page
or the Set Points
Remote Set Point Over/Under Level
125.2 Range
70 The remote set point value is over
or under range. Flashing stops Contact the Service
automatically when the remote set Organization
point input comes back into range.

Option error Press any key

OPtn Communications to the option
Err board have failed.

t.Err Auto-tune error

The number displayed indicates the
1 type of error present – see Table 2.1
in Section 2.7.

2-7
 2 OPERATOR MODE
2.1 Introduction
Operator Mode (Level 1) is the normal day-to-day mode of the COMMANDER 250.

Frames displayed in level 1 are determined by the control strategy which is

selected during configuration of the instrument – see Section 4.

Note. Only the operating frames relevant to the configured strategy are
displayed in Operator Mode.

The five control strategies are:

• Standard controller – page 9

• Heat/Cool controller – page 10

• Remote Set Point controller – page 12

• Profile controller – page 14

• Multiple Fixed Set Points controller – page 16

2-8
 2 OPERATOR MODE…

2.2 Standard Controller

Process Variable Value
Auto 125.2
125.8 Control Set Point Value (Local set point)
[Set point low limit to set point high limit]

Process Variable Value

125.2
Man
70 Control Output Value (%)
OP1 [0 to 100% (–10% to 110% for analog output)]
Adjustable in manual mode only.

•1 Ramping Set Point Value (Read only)

SPrP The actual set point value is displayed i.e. the
120.5 instantaneous value the controller is working to.

Security Code
CodE [0 to 9999]
0 Select the appropriate security code to access:
Auto-tune enable frame (Level 1),
Set Up mode (Levels 2, 3, 4).

Auto-tune Enable
AtnE ON – Auto-tune on
OFF OFF – Auto-tune off
Refer to page 16 for the Auto-tune procedure.

Level 1 (Operator mode)

Refer to Section 3 for levels 2, 3 and 4.
LEV1
OPEr LEV2 LEV3 LEV4
tUnE SEtP PrFL

•1 Not displayed if the ramping set point facility is turned off – refer to
Section 3.3.

2-9
 …2 OPERATOR MODE

2.3 Heat/Cool Controller

Process Variable Value
Auto 125.2
125.8 Control Set Point Value (Local set point)
[Set point low limit to set point high limit]

Process Variable Value

125.2
70 Control Output Value (Heat %)
OP1 (Heat)
[0% to 100% (0% to 110% for analog output)]
Man
If adjusted below 0% the 'Cool' frame is displayed.
125.2
-30 Control Output 2 Value (Cool %)
[0% to –100% (0% to –110% for analog output)]
OP2 (Cool)
If adjusted above 0% the 'Heat' frame is displayed.

•1 Ramping Set Point Value (Read only)

SPrP The actual set point value is displayed i.e. the
120.5 instantaneous value the controller is working to.

CodE
0 Continued on next page.

•1 Not displayed if the ramping set point facility is turned off – refer to
Section 3.3.

2-10
 2 OPERATOR MODE…

…2.3 Heat/Cool Controller

Security Code
CodE [0 to 9999]
0 Select the appropriate security code to access:
Auto-tune enable frame (Level 1),
Set Up mode (Levels 2, 3, 4).

Auto-tune Enable
AtnE ON – Auto-tune on
OFF OFF – Auto-tune off
Refer to page 16 for the Auto-tune procedure.

Level 1 (Operator mode)

See Section 3 for levels 2, 3 and 4.
LEV1
OPEr LEV2 LEV3 LEV4
tUnE SEtP PrFL

2-11
 …2 OPERATOR MODE

2.4 Remote Set Point Controller

Process Variable Value

Auto
125.2
125.8 Control Set Point Value
[Set point low to set point high limit]
Adjustable in local Set Point Mode only.

Process Variable Value

125.2
Man
70 Control Output Value (%)
OP1 [0% to 100% (–10% to 110% for analog output)]
Adjustable in manual mode only.

Remote Set Point Selection

rSPn rSPY – Remote Set Point
123.4 rSPn – Local Set Point
Local or remote set point can also be selected using
a digital input.

The option to change the set point selection at this

frame can be disabled in the configuration level.

Remote Set Point Value (read only)

SPrP Continued on next page…

120.5

Note.
If the remote set point input fails while selected, the controller selects the local
set point value automatically. The upper display changes to rSP.F and the
lower display flashes. When the fault condition is removed the remote set point
is re-selected automatically. To clear the error condition while the remote set
point input is still outside its allowed range, select the local set point by pressing
the key (rSP.n is displayed).

2-12
 2 OPERATOR MODE…

…2.4 Remote Set Point Controller

•1 Ramping Set Point Value (Read only)

SPrP The actual set point value is displayed i.e. the
120.5 instantaneous value the controller is working to.

Security Code
CodE [0 to 9999]
0 Select the appropriate security code to access:
Auto-tune enable frame (Level 1),
Set Up mode (Levels 2, 3, 4).

Auto-tune Enable
AtnE ON – Auto-tune on
OFF OFF – Auto-tune off
Refer to page 16 for the Auto-tune procedure.

Level 1 (Operator mode)

LEV1 See Section 3 for levels 2, 3 and 4.
OPEr LEV2 LEV3 LEV4
tUnE SEtP PrFL

•1 Not displayed if the ramping set point facility is turned off – refer to
Section 3.3.

2-13
 …2 OPERATOR MODE

2.5 Profile Controller

Process Variable Value

Auto
125.2
125.8 Control Set Point Value
[Set point low limit to set point high limit]

Process Variable Value

125.2
Man 70 Control Output Value (%)
OP1 [0% to 100% (–10% to 110% for analog output)]
Adjustable in manual mode only.

Profile Segment Number (1 to 4) currently active

SG 1
StoP Profile Status
SG 1 SG 1 SG 1
StoP run HOLd

StOP – Profile inactive – the control set point

is equal to the local set point value
when the profile is not running.
run – Profile active – currently operating on
the segment indicated.
HOLD – Profile hold – pauses the current ramp
or soak mode by putting it into 'Hold'
mode. The guaranteed ramp soak
feature can also be used to put the profile
into a 'Hold' mode until the process
variable comes back within the
hysteresis band.

Note. The profile status can be changed using

a digital input.

SPrP Continued on next page…

120.5

2-14
 2 OPERATOR MODE…

…2.5 Profile Controller

•1 Ramping Set Point Value (Read only)

SPrP The actual set point value is displayed i.e. the
120.5 instantaneous value the controller is working to.

Security Code
CodE [0 to 9999]
0 Select the appropriate security code to access:
Auto-tune enable frame (Level 1),
Set Up mode (Levels 2, 3, 4).

Auto-tune Enable
AtnE ON – Auto-tune on
OFF OFF – Auto-tune off
Refer to page 16 for the Auto-tune procedure.

Level 1 (Operator mode)

LEV1 See Section 3 for levels 2, 3 and 4.
OPEr LEV2 LEV3 LEV4
tUnE SEtP PrFL

•1 Not displayed if the ramping set point facility is turned off – refer to
Section 3.3.

2-15
 …2 OPERATOR MODE

2.6 Multiple Fixed Set Points Controller

If the Multiple Fixed Set Points Controller type is selected during configuration, four
fixed control set points can be set – see Section 4.4.

Process Variable Value

Auto 125.2
125.8 Fixed Control Set Point Selected

SP-1 SP-2 SP-3 SP-4

100.3 200.1 300.2 400.5

Notes.
a) The top display momentarily displays the set
point selected before reverting to the display
of the process variable value.

b) A digital input can also be used to select the

fixed set points.

Process Variable Value

125.2
Man 70 Control Output Value (%)
OP1 [0% to 100% (–10% to 110% for analog output)]
Adjustable in manual mode only.

•1 Ramping Set Point Value (Read only)

SPrP The actual set point value is displayed i.e. the
12.05 instantaneous value the controller is working to.

CodE
Continued on next page…
0

•1 Not displayed if the ramping set point facility is turned off – refer to
Section 3.3.

2-16
 2 OPERATOR MODE…

…2.6 Multiple Fixed Set Points Controller

Security Code
CodE [0 to 9999]
0 Select the appropriate security code to access:
Auto-tune enable frame (Level 1),
Set Up Mode (Levels 2, 3, 4).

Auto-tune Enable
AtnE ON – Auto-tune on
OFF OFF – Auto-tune off
Refer to page 16 for the Auto-tune procedure.

Level 1 (Operator mode)

See Section 3 for Levels 2, 3 and 4.
LEV1
OPEr LEV2 LEV3 LEV4
tUnE SEtP PrFL

2-17
 …2 OPERATOR MODE

2.7 Auto-tune

Information.
• Auto-tune optimizes process control by monitoring process performance
and automatically updates the control parameters.

• Before starting auto-tune, the process variable must be stable (±2% of

engineering range).

1 – 'Start up' auto-tune 2 – 'At set point' auto-tune

(from manual mode) (from manual or automatic mode)
PV PV
+2%
SP - 2% SP

+2%
- 2%
t t
1a – Stable process before auto-tune 2a – Stable process before auto-tune
1/4 wave
PV damping PV
SP SP

Controlling to Controlling
Set Point to Set Point

Auto-tune Auto-tune
complete complete
t t
1b – Process response during auto-tune 2b – Process response during auto-tune

PV

SP
Note. The time 1/4 wave
taken to complete damping
autotune depends
upon the system
response time.
t
Typical process response after auto-tune

Fig 2.1 Typical Auto-tune Cycles

2-18
 2 OPERATOR MODE

…2.7 Auto-tune
From Security Code frame (any Operating page)
CodE The correct password must be entered to access the
x auto-tune frame.

AtnE Auto-tune Enable

ON – Auto-tune on
OFF OFF – Auto-tune off
Auto-tune can be stopped at any time by pressing the
key.

Settings for P + I control only

To tune for P + I control only, set the derivative term
LEV1 to 'OFF' in the Tuning Level – see Section 3.2.

OPEr LEV2 LEV3 LEV4

tUnE SEtP PrFL

Notes.
• On completion the controller enters auto control mode and begins to control
the process using the new PID values. For fine-tuning – see Section 3.

• For heat/cool control the cool proportional band is set to the same value as
the heat proportional band (this value may need modification).

• If an error occurs during auto-tune, the controller reverts to manual mode

with the control output set to the configured output value. An error message
is displayed – see Table 2.1.

Error Description Error Description

1 PV failed during auto-tune 7 A resultant P, I or D value was calculated
2 Auto-tune has timed out during an auto- out of range
tune step 8 PV limit exceeded (At start up auto-tune)
3 Process too noisy to auto-tune 9 Controller put into configuration mode
4 Process too fast to auto-tune 10 Auto-tune terminated by user
5 Process too slow to auto-tune 11 PV is changing in the wrong direction
6 PV deviated from set point by >25% eng. during step test
span during frequency response test

Table 2.1 Auto-tune Error Codes

2-19
8 3 SET UP MODE
3.1 Introduction
To access the Set Up Mode (Levels 2, 3 and 4) the correct password must be
entered in the security code frame (the default password code is 0). Refer to the
fold-out sheet at the back of this manual for the contents of these levels.

LEV3
SEtP
LEV2 Refer to the fold-out sheet
tUnE for the contents of each level
LEV1 Correct Password
OPEr

CodE
0

3.2 Tuning (Level 2)

LEV2 Level 2 – Tuning Level

tUnE Note. To select this frame from anywhere in
this page, press the key for a few seconds.

Cycle Time

•1
cYc.1 Heat Time Proportioning Output
[1.0 to 300.0 seconds (<1.0 = 'On/Off' control)]
5.0

•2
cYc.2 Cool Time Proportioning Output
[1.0 to 300.0 seconds (<1.0 = 'On/Off control)]
5.0

HYSt
0.1 Continued on next page.

•1 Only displayed if output 1 is assigned to a relay or logic output.

•2 Only displayed if heat/cool hardware configuration is selected.

2-20
…3 SET UP MODE 8
…3.2 Tuning (Level 2) – Fig. 3.2

•1 On/Off Hysteresis Value

HYSt
(used for both heat and cool outputs)
0.1 [In engineering units]

PV
Set Point
Hysteresis Value

ON Reverse Acting
Control Output
OFF

Proportional Band
Enter the proportional band value for the heat and
cool outputs.

Pb-H Heat Output (Output 1)

[0.1% to 999.9%]
100.0

•2 Cool Output (Output 2)

Pb-c
[0.1% to 999.9%]
100.0

Intr Continued on next page.

30

•1 Only displayed if On/Off control is selected for either output.

•2 Only displayed if heat/cool hardware configuration is selected.

2-21
8 …3 SET UP MODE

…3.2 Tuning (Level 2)

Integral Action Time

Intr [1 to 7200 seconds or OFF (OFF=0)]
30

Manual Reset Value

rSEt [0% to 100% or –100% to +100% for heat/cool]
50 This value is applied as a bias to the control output.

Note. Manual reset is applied with integral

action both on and off.

Derivative Action Time

dr1U [0.1 to 999.9 seconds or OFF (OFF=0)]
1.0

•1 Overlap for Heat/Cool Control

0.LAP [–20.0% to +20.0%]
0.0 This frame defines the portion of the proportional
band (Proportional band heat + Proportional band
cool) over which both outputs are active – see Fig.
3.1. Neither output is active in the deadband.

A positive value gives an overlap and a negative

value a deadband.

•1 Only displayed if a heat/cool hardware configuration is selected.

2-22
 3 SET UP MODE… 8
a) Overlap
Pb-h
Proportional Band (Heat)
Output Power (%)

Pb-c
Output 1 Proportional Band (Cool)
(heat) Output 2 (cool)

Output 2
(cool) Output 1 (heat)

OLAP Process Variable

Overlap (positive value)

b) Deadband
Pb-h Pb-c
Output Power (%)

Proportional Band Heat Proportional Band Cool

Output 1 Output 2

Output 2 Output 1

OLAP Process Variable

Deadband (negative value)

c) Output 2 on/off control

Pb-h
Output Power (%)

Proportional Band Heat

Output 1 Output 2
O/P2 OFF

O/P2 ON

Output 2 Output 1

HYSt Process Variable

ON/OFF' Hysteresis (0% overlap)
Positive values Negative values
OLAP
Overlap/Deadband

Fig. 3.1 Proportional Band & Deadband/Overlap – Heat/Cool Control Only

2-23
8 …3 SET UP MODE

3.3 Set Points (Level 3)

Level 3 – Set Points Level

LEV3
SEtP Note. To select this frame from anywhere in
this page, press the key for a few seconds.

Local Set Point Value

LSPt [Within set point high and low limits, in engineering
125.8 units]

•1 Remote Set Point Selection

rSP.n Set Point Type:
145.8 rSP.Y – remote set point
rSP.n – local set point

Remote set point value.

Alarm 1 Trip Point

A1.hP Alarm type:
800.0 A1.hP = High process alarm
A1.LP = Low process alarm
A1.hd = High deviation alarm
A1.Ld = Low deviation alarm
A1.Lb = Loop break alarm

Trip Point:
Process & deviation alarms [in engineering units]
Loop break alarm [1 to 9999 seconds]

A1.HY Continued on next page.

270.0

•1 Only displayed if the remote set point option is selected.

2-24
 3 SET UP MODE… 8
…3.3 Set Points (Level 3)

•1 A1.HY Alarm 1 Hysteresis Value

[in engineering units]
162.0

A2.hP Alarm 2 Trip Point

Alarm type:
200.0 A2.hP = High process alarm
A2.LP = Low process alarm
A2.hd = High deviation alarm
A2.Ld = Low deviation alarm
A2.Lb = Loop break alarm

Trip Point:
Process & deviation alarms [in engineering units]
Loop break alarm [1 to 9999 seconds]

•1 A2.HY Alarm 2 Hysteresis Value

[in engineering units]
18.5

•2 Remote Set Point Input Ratio and Bias

rAt0 The remote set point value =
1.000 ratio x remote set point input + bias.
Ratio
[0.001 to 9.999]
•2
bIAS Bias
0.0 [in engineering units]

r.rtE Continued on next page.

OFF

•1 Only displayed if custom alarm hysteresis is selected – see section 4.3.2,

not displayed if Loop Break Alarm type selected.
•2 Only displayed if the remote set point option is selected.

2-25
8 …3 SET UP MODE

…3.3 Set Points Level

r.rtE Ramp Rate (for ramping set point facility)

[1 to 9999 engineering units per hour, or OFF]
0FF
The ramping set point facility can be used to prevent
a large disturbance to the control output when the set
point value is changed. This only applies to the local
and multiple fixed set points.

Note. For remote set points, the ramp rate is

applicable only when switching from remote to local
mode, not from local to remote.
PV
Displayed Local Set Point Value
300

200

Actual (Ramping) Set Point Value

100
used by PID Algorithm*

0
1 Hour Time

* e.g. Ramp Rate = 200 Increments/Hour

O.AdJ Offset Adjustment

An offset can be applied to the process variable input
0.3 to enable spot calibration or the removal of system
errors.

[±10% of engineering range in engineering units]

2-26
 3 SET UP MODE… 8
3.4 Profile (Level 4)
A four segment ramp/soak profile facility is provided. This level can only be
accessed if the profile option is selected in the configuration level. The four
segments are fixed as ramps or soaks as follows:

End.1
Set Point
Value SKt.2
rtE.3 End.3
rtE.1
SKt.2
1 2 3 4
Time
Str.1

LEV4 Level 4 – Profile Level

PrFL Note. To select to this frame from anywhere in

this page, press the key for a few seconds.

•1 Start value for 1st Segment (ramp).

Str.1 [Within display range (in engineering units)]
100.0
Enter the start value required.

End.1 End Value for 1st Segment (ramp).

[Within display range (in engineering units)]
200.0
Enter the end value required.

rtE.1
Continued on next page.
10.0
•1 With the self-seeking set point facility enabled, the first ramp starts at the
current process variable value instead of the start value for the 1st segment.

2-27
8 …3 SET UP MODE

…3.4 Profile (Level 4)

•1 Ramp Rate for 1st Segment.

rtE.1 [Engineering units* ]
40.00
Enter the ramp rate required.
* The time option Eng Units/hr or Eng Units/min is
set in the configuration level – see section 4.3.2.
Set Point
Value
1st Segment
80

40

0
2 Min Time
Example. Required Ramp Rate 40°C/min
Ramp Rate set to 40, Time Option set to 'Min' – see section 4.3.2

Soak Time for 2nd Segment.

SKt.2 [0 to 999.9 minutes or hours]*
60.00

End Value for 3rd Segment (ramp).

End.3 [Within display range (in engineering units)]
100.0

Ramp Rate for 3rd Segment.

rtE.3 [Engineering units/hour or /minute]*
20.00
* Depending on the time option selected in the
configuration level.
SKt.4
30.00 Continued on next page.

•1 The engineering value is shown with an extra decimal place (up to a

maximum of 3) for greater accuracy in setting the ramp rate.

2-28
 3 SET UP MODE 8
…3.4 Profile (Level 4)

•2 Soak Time for 4th Segment.

SKt.4 [0 to 999.9 minutes or hours]*
30.00 * Depending on the time option selected in the
configuration level.

Self Seeking Set Point Enable.

S.S.S.P YES – enable self seeking set point
YES NO – disable self seeking set point
When enabled the controller inserts the current
process variable value as the starting point on
initiation of the profile (instead of the start value for
segment 1).

Profile Hysteresis for Guaranteed Ramp/Soak.

P.HYS [In engineering units or OFF = 0]
OFF
If the process variable deviates from the set point by
more than the value set, the program is suspended
but continues automatically when the process
variable returns within the set limits. The hysteresis
value applies above and below set point under all
program conditions.

Number of Program Repeats

rPtS [0 to 99 or infinite (InFt> 100]
0

•2 The engineering value is shown with an extra decimal place (up to a

maximum of 3) for greater accuracy in setting the ramp rate.

2-29
 4 CONFIGURATION MODE
4.1 Introduction
The Configuration Mode comprises two levels (5 and 6) as shown in Fig. 4.2.

Level 5 is divided into four frames. For most simple applications it is only necessary
to set up the parameters in the first frame.

Note.
When in the configuration level:
• All the l.e.d. indicators flash.

• All relays and logic outputs are turned off.

• The analog output reverts to 0% (4mA) output level.

4.2 Accessing the Configuration Mode – Fig. 4.1

To access the Configuration Mode set the security switch to the 'Configure' position
(levels 1 to 4 cannot be accessed from this setting). When the configuration
parameters are programmed, reset the security switch to the 'Normal' position. The
Operating page is displayed automatically .

Normal

Configure

Fig. 4.1 Accessing the Configuration Mode (Config./Normal Switch)

2-30
 4 CONFIGURATION MODE…

LEV6
CnFG
LEV5
CnFG EnGH
100.0
Hardware Assignment and AbCd
Input Type ---- EnGL
0.0 SP-3
Alarms and Set Point EFGH 30.0
Types ---- rt1.H
100.0 SP-4
Operator Access and JKLn 40.0
Control Action ---- rt1.L
0.0 OPI.H
Digital Input and PrSt 100
Serial Communications ---- rt2.H
200.0 OP2.H
100
rt2.L
0.0 C-OP
0
SP-H
100.0 A.PAS
0
SP-L
0.0 S.PAS
0
SP-1
10.0 Addr
1
SP-2
20.0

Fig. 4.2 Configuration Frames (Levels 5 and 6)

2-31
 …4 CONFIGURATION MODE

4.3 Basic Hardware and Configuration (Level 5)

4.3.1 Hardware Assignment and Input Type – Fig. 4.3

LEV5 Level 5 – Configuration

CnFG Note. To select this frame from anywhere in

this page, press the key for a few seconds.

'ABCD' Settings

AbCd AbCd AbCd AbCd

2400 2400 2400 2400
The parameter to be changed is indicated by the
letter which is flashing. Parameter options are shown
in Fig. 4.3.
A = Hardware configuration
b = Input type and range
C = Temperature units
d = Process variable display decimal places

Notes.
Note 1. When the input type (parameter b) is
changed, the range is set automatically to the
maximum permissable for the input type selected.

Note 2. For custom settings contact the local

distributor.

EFGH Continued on page 34.

----

2-32
 4 CONFIGURATION MODE…

A – Hardware Configuration
AbCd
2400
Frequency Rly 1 Rly 2* Rly 3* Logic O/P An. O/P 1 An. O/P 2* Control Type
50Hz 60Hz
1 A O/P 1 Alm 1 Alm 2 O/P 1 PV SP Time Prop. or On/Off
2 b Alm 1 Alm 2 None None O/P 1 PV Analog Prop.
3 C O/P 1 O/P2 Alm 1 O/P 1 PV SP Heat – Time Prop.
Cool – Time Prop.
4 d O/P2 Alm 1 Alm 2 O/P2 O/P 1 PV Heat – Analog
Cool – TP or On/Off
5 E Alm 1 Alm 2 None O/P 1 PV SP Alm Unit or Logic O/P
Time Prop.
U Custom Custom Custom Custom Custom Custom Custom
* Only available if option board is fitted

B – Input Type and Range Configuration

AbCd
2400
Display Display
b THC Type B 1 0 to 20 mA
E THC Type E 2 4 to 20 mA
J THC Type J 3 0 to 5 V
K THC Type K 4 1 to 5 V
n THC Type N 6 0 to 50 mV
r THC Type R 7 4 to 20 mA (square root lineariser)
S THC Type S U Custom Configuration
t THC Type T
P PT100 RTD

C – Temperature Units D – Process Variable Display

AbCd AbCd Decimal Places
2400 2400
Display Temperature Units Display
C Degrees C* 0 xxxx
F Degrees F* 1 xxx . x
0 No temperature units 2 xx . xx
3 x . xxx
* Temperature inputs only

Fig. 4.3 Hardware Assignment and Input Type

2-33
 …4 CONFIGURATION MODE

4.3.2 Alarms and Set Point Types – Fig. 4.4

Note. All relays are de-energised in the alarm state.

'EFGH' Settings

EFGH EFGH EFGH EFGH

3241 3241 3241 3241
The parameter to be changed is indicated by the
letter which is flashing. Parameter options are
shown in Fig. 4.4.
E = Alarm 1 type
F = Alarm 2 type
G = Alarm Hysteresis
H = Set Point type

Note. For custom settings contact the local

distributor.

JKLn Continued on page 38.

----

2-34
 4 CONFIGURATION MODE…

E – Alarm 1 Type* F – Alarm 2 Type*

EFGH EFGH
3241 3241
Display Display
0 None 0 None
1 High Process 1 High Process
2 Low Process 2 Low Process
3 High Deviation 3 High Deviation
4 Low Deviation 4 Low Deviation
5 Loop Break 5 Loop Break

* Refer to Figs. 4.5 and 4.6 for alarm action

G – Alarm Hysteresis
EFGH
3241 Note 1. When custom alarm
Display hysteresis is selected, the alarm
0 None hysteresis values are set
1 0.1% individually in the set up level
2 0.2% Value in % of – see section 3.3
3 0.5% engineering
4 1.0% range
5 2.0%
6 5.0%
U Custom Value in engineering units 1

H – Set Point Type

EFGH
3241
Display
0 Local Set Point Only
1 Local + Remote Set Point (no Remote Set Point Tracking)**
2
2 Local + Remote Set Point (with Remote Set Point Tracking)**
3 Multiple Fixed Set Points
4 Ramp/Soak (Time Units in Minutes)
5 Ramp/Soak (Time Units in Hours)
**Only available if option board is fitted. Remote set point input is 4 to 20 mA

Note 2. With remote set point tracking enabled the local set point
tracks the remote set point when in the remote set point mode.

Fig. 4.4 Alarms and Set Point Types

2-35
 …4 CONFIGURATION MODE

…4.3.2 Alarms and Set Point Types – Fig. 4.4

Note. All relays are de-energised in the alarm state.

Loop Break Alarm

The loop break alarm indicates a fault in the control loop (e.g. failure of a heating
element in a furnace). If the control output remains at maximum or minimum for a
time exceeding the trip value (in seconds) without any response in the process
value, the loop break alarm is activated.

Process and Deviation Alarms (High/Low) – Figs 4.5 and 4.6

Hysteresis
Trip point
Hysteresis

Process
Variable

Alarm on
High Process
Alarm off

Alarm on
Low Process
Alarm off

Fig. 4.5 High and Low Process Alarm Action

2-36
 4 CONFIGURATION MODE…

High Deviation
+ve Trip Value
Hysteresis

Process
Variable
Control Set
Point
High Deviation
–ve Trip Value
Hysteresis

Alarm on
Positive
Alarm off Trip Value
Negative Alarm on
Trip Value
Alarm off

High Deviation Alarm

Process
Variable Hysteresis
Low Deviation
+ve Trip Value

Control Set
Point

Hysteresis
Low Deviation
–ve Trip Value

Alarm on
Positive Trip Value
Alarm off

Alarm on
Negative
Trip Value Alarm off

Low Deviation Alarm

Fig. 4.6 High and Low Deviation Alarm Action

2-37
 …4 CONFIGURATION MODE

4.3.3 Operator Access and Control Action – Fig. 4.7

'JKLN' Settings

JKLn JKLn JKLn JKLn

2310 2310 2310 2310
The parameter to be changed is indicated by the letter
which is flashing. Parameter options are shown in Fig. 4.7.
J = Power recovery mode
K = Operator selection enable – control functions
L = Operator selection enable – set point functions
n = Control action

Note. For custom settings contact the local

distributor.

PrSt Continued on page 40.

----

2-38
 4 CONFIGURATION MODE…

J – Power Recovery Mode K – Operator Selection Enable

JKLn JKLn Control Functions
2310 2310
Display Mode Display Auto/Manual and Autotune
0 Last Mode 0 Enable Both Functions
1 Manual with Last Output 1 Disable A/M, Enable Auto-tune
2 Manual with 0.0% Output 2 Enable A/M, Disable Auto-tune
3 Manual with 100.0% Output 3 Disable Both Functions
4 Auto
U Custom

L – Operator Selection Enable – Set Point Functions

JKLn
2310
Display Local Set Point Adjustment and Local/Remote Set Point Selection
0 Enable Both Functions
1 Disable Set Point Adjust, Enable Local/Remote Selection
2 Enable Set Point Adjust, Disable Local Remote Function
3 Disable Both Functions

N – Control Action
JKLn
2310
Display Heat Action Cool Action
0 Reverse Direct
1 Direct Reverse

Fig. 4.7 Operator Access and Control Action

2-39
 …4 CONFIGURATION MODE

4.3.4 Digital Input and Serial Communications – Fig. 4.8

'PRST' Settings

PrSt PrSt PrSt PrSt

2100 2100 2100 2100
The parameter to be changed is indicated by the
LEV5
letter which is flashing. Parameter options are shown
CnFG
in Fig. 4.8.
P = Digital input function
r = Analog input digital filter
S = Serial communications configuration
t = Serial communication parity

Note. For custom settings contact the local

distributor.

Lock
Manual Run
Unlock
Auto Hold
1 Auto/Manual 4 Ramp/Soak Run-Hold 6 Front Panel Lockout

Remote Run Select next

Set Point
Local Stop
2 Local/Remote 5 Ramp/Soak Run-Hold 7 Select Fixed Set Points

Start

Stop
3 Auto-tune Start/Stop

Information. All digital input functions except 6 are triggered on the

rising/falling edge, to enable the front panel keys to change the function
when the digital input is operational.

Fig. 4.8 Digital Inputs

2-40
 4 CONFIGURATION MODE…

P – Digital Input Functions

PrSt
2100
Display Function
0 None
1 Auto/Manual
2 Local/Remote
3 Auto-tune Start
4 Ramp/Soak Run-Hold
5 Ramp/Soak Run-Stop
6 Front Panel Lockout
7 Select Fixed Set Points

R – Analog Input Digital Filter

PrSt
2100
Display
0 0 seconds
1 1 second
2 2 seconds
5 5 seconds Input filter averages the process
A 10 seconds variable input values over the time set
B 20 seconds
C 40 seconds
D 60 seconds

S – Serial Communication T – Serial Communications

PrSt Configuration PrSt Parity
2100 2100
Display Baud Rate, 2/4 Wire Display
0 Off 0 None
1 2400, 2 Wire 1 Odd
2 2400, 4 Wire 2 Even
3 9600, 2 Wire
4 9600, 4 Wire

Fig. 4.9 Digital Input and Serial Communications

2-41
 …4 CONFIGURATION MODE

4.4 Ranges and Passwords (Level 6)

LEV6 Ranges and Limits

CnFG

•1 Engineering (Display) Range

EnGH
100.0 High Value
[–999 to 9999]

EnGL
0.0 Low Value
[–999 to 9999]

rt1.H Continued on next page…

100.0

•1 The engineering range high and low values are automatically set to the
maximum allowed value when thermocouple or RTD is selected in the
configuration level – see Section 4.3.1.

2-42
 4 CONFIGURATION MODE…

…4.4 Ranges and Passwords (Level 6)

•1 Retransmission Range
rt1.H The retransmission range defines engineering range
100.0 to be transmitted

Retransmission High (20mA) Analog Output 1

[–999 to 9999 (in engineering units)]

•1
rt1.L Retransmission Low (4mA) Analog Output 1
0.0 [–999 to 9999 (in engineering units)]

•2 rt2.H Retransmission High (20mA) Analog Output 2

200.0 [–999 to 9999 (in engineering units)]

•2 rt2.L Retransmission Low (4mA) Analog Output 2

0.0 [–999 to 9999 (in engineering units)]

SP-H
Continued on next page…
100.0

•1 Only displayed if the analog output is configured to retransmit the

process variable or control set point value.

•2 Only displayed if the retransmission option board is fitted.

2-43
 …4 CONFIGURATION MODE

…4.4 Ranges and Passwords (Level 6)

Set Point Limit

The Set Point Limit defines limits within which the
local set point can be adjusted (these limits also
apply to remote set point).

•1 High Limit
SP-H
[–999 to 9999]
100.0

•1 Low Limit
SP-L
[–999 to 9999]
0.0

Fixed Set Point Values (1 to 4)

Select the set point values required in the multiple
fixed set point facility.

•2 Fixed Set Point 1

SP-1
[–999 to 9999 (in engineering units)]
10.0

•2 Fixed Set Point 4

SP-4
[–999 to 9999 (in engineering units)]
30.0

OP1.H
Continued on next page…
100.0

•1 This limit applies to the local and remote set point values.

•2 Only displayed if the multiple fixed set point facility is selected.

2-44
 4 CONFIGURATION MODE

…4.4 Ranges and Passwords (Level 6)

•1
OP1.H Output 1 (Heat) High Limit
[0% to 110%]
100.0

•1
OP2.H Output 2 (Cool) High Limit
[0% to 110%]
•2 100.0

C-OP Configured Output

[–10% (–110% for heat/cool) to 110% or LASt
0 (default)]
This output value is used when:
– Manual control is selected using a digital input,
– the process variable input fails,
– the auto-tune fails.

A.PAS Auto-Tune Password

[0 to 9999 (default 0)]
0
Enables access to the auto-tune facility in the
operating level (Level 1).

S.PAS Setup Password

[0 to 9999 (default 0)]
0
This password enables access to the setup levels
(levels 2, 3, and 4) and to the auto tune facility.

Addr MODBUS Address

[1 to 99]
1
This frame allows the MODBUS address to be set.
•1 This value only applies in automatic mode.
The low limit is automatically set to 0.0% (–10% for analog outputs).

•2 Only displayed if a heat/cool hardware configuration is selected.

2-45
 5 INSTALLATION
5.1 Siting – Figs. 5.1 and 5.2

Close to the Sensor Sensor

At Eye Level

Avoid Vibration

Fig. 5.1 General Requirements

2-46
 5 INSTALLATION…

…5.1 Siting – Figs. 5.1 and 5.2

55°C (131°F)
Max.

0°C (32°F) Temperature Limits

Min.

0 to 90% RH
Humidity Limits

IP66/NEMA4X
(front panel)
Environmental Limits
IP20
(rear)

Use Screened Cable

+

Fig. 5.2 Environmental Requirements

2-47
 …5 INSTALLATION

5.2 Mounting – Figs. 5.3 and 5.4

The instrument is designed for panel mounting (see Fig. 5.4). Overall dimensions
are shown in Fig. 5.3.

Dimensions in mm (in.) 17.5

(0.69) 122.5 (4.82)

96 91.8 (3.61)
(3.78)

5.0
96 (3.78) (0.2)

+0.8
92 (3.622 +0.03 )
–0.0 –0.0

+0.8
92 Panel
–0.0
Cut-out
(3.622 +0.03 )
–0.0

30 (1.18)

14 (0.55)

Fig. 5.3 Overall Dimensions

2-48
 5 INSTALLATION…

…5.2 Mounting – Figs. 5.3 and 5.4

1 Cut a hole in the panel

(see Fig. 5.3 for dimensions).
Instruments may be close
stacked to DIN 43835

2 Insert the instrument

into the panel cut-out

3 Fit the panel clamps, ensuring that the lugs

are located correctly in their slots

4 Secure the panel clamp using the retaining screws.

The rubber friction sleeve prevents over-tightening.

Fig. 5.4 Mounting Details

2-49
 …5 INSTALLATION

EC Directive 89/336/EEC

In order to meet the requirements of the EC Directive 89/336/EEC for EMC

regulations, this product must not be used in a non-industrial environment.

5.3 Removing the Instrument from the Case – Fig. 5.5

1 Release the jacking screw cover

2 Turn the jacking screw anticlockwise to pull

the instrument from the case

Fig. 5.5 Removing the Instrument from the Case

2-50
 5 INSTALLATION…

5.4 Electrical Connections – Fig. 5.6 (overleaf)

Warning. Before making any connections, ensure that the power

supply, any powered control circuits and high common mode voltages are
switched off.

Note. If it is not possible to avoid strong electrical and magnetic fields,

screened cables within earthed metal conduit must be used.

5.5 Relays, Arc Suppression and Outputs

5.5.1 Relay Contact Ratings
Relay contacts are rated at:

115/230V AC at 5A (non-inductive).

250V DC 25W max.

5.5.2 Arc Suppression

Arc suppression components are fitted to relays 2 and 3 only. If relay 1 is required
to switch inductive loads, the arc suppression components supplied must be fitted.

5.5.3 Logic Output

18V DC at 20mA.

Min load 900Ω.

Isolated from inputs (not isolated from analog O/P 1),

dielectric strength – 500V d.c. for 1 minute.

5.5.4 Control or Retransmission Analog Outputs

Max. load 15V (750Ω at 20mA).

Analog O/P 1 – Isolated from inputs (not isolated from logic O/P),
dielectric strength – 500V d.c. for 1 minute.

Analog O/P 2 – Non-isolated.

2-51
 …5 INSTALLATION

Auxiliary – 25 1 –
Input
+ Analog Input
(Remote set point) + 26 2
(see below)
Digital – 27 3 RTD1
Input + +
28 4 Transmitter PSU

N/O 29 5 + +
Relay Analog Logic
C 30 6 – Output 1 Output
Output 2
N/C 31 7 –

Analog + RS485 + 32 8 N/O

O/P 2 TX Relay
N/O – 33 9 C Output 1 ***
Relay C RS485 + 34 10 N/C
O/P 3
RX 85 to
N/C – 35 11 N 265V a.c. –
Analog 24V d.c.
– Mains
O/P 2 RS485 C 36 12 L +
Supply
1 A fuse

Note. Analog output 1 and the logic output use a common positive
terminal, capable of driving both outputs simultaneously.

THC 3-lead 2-lead RTD Milliamps * Milliamps

millivolts RTD and resistance
and volts
1 3rd lead RTD – –
–
** 100Ω ** 100Ω

2 + RTD – RTD – +
–
RTD + 2-wire
3 RTD + Tx
transmitter
+
4
* Using internal transmitter power supply
** Use 100Ω shunt resistor provided with the instrument
*** Fit the arc suppression component supplied with the instrument

Fig. 5.6 Electrical Connections

2-52
Customer Support CUSTOMER SETUP LOG 8

✍
ABB Ltd provides a comprehensive after
sales service via our Worldwide Service LEV4
Organization. Contact one of the following
offices for details of your nearest Service
PrFL
and Repair Centre. LEV3
SEtP Str1
United Kingdom LEV2 100.0
ABB Ltd LSPt
Tel: +44 (0)1480 475 321 tUnE End1
Fax: +44 (0)1480 470 787 LEV1 125.8
rYc1 200.0
OPEr rsPn
United States of America 5.0 rtE1
ABB Automation Inc. 145.8
Instrumentation Division cYc2 10.0
Tel: +1 215 674 6000 5.0 A1hP
Fax: +1 215 674 7183 800.0 SKt2
CodE 60.0
0 HYSt
Client Warranty 0.1 A2hP
200.0 End3
Prior to installation, the equipment referred to in this manual must be stored in a Correct 100.0
clean, dry environment, in accordance with the Company's published specification. password Pb-h
100.0 rAtO
Periodic checks must be made on the equipment's condition. rtE3
AtnE 1.000
In the event of a failure under warranty, the following documentation must be 20.0
provided as substantiation: OFF Pb-c
100.0 bIAS
1. A listing evidencing process operation and alarm logs at time of failure. 0.0 SKt4
2. Copies of operating and maintenance records relating to the alleged faulty unit. Intr 30.0
30 rrtE
OFF SSSP
rSEt YES
50.0 OAdJ
0.3 PHYS
drIV YES
1.0 rPt5
OLAP 0
0.0 Company Standard settings are
shown in the lower display

Instrument Serial Number:

Product Code: C 250 / /

2-53
 CUSTOMER CONFIGURATION LOG

LEV5
CnFG
LEV6
CnFG
EnGH
✍
100.0
AbCd
---- EnGL
0.0
EFGH
---- rt1.H SP-3
100.0 30.0
JKLn
---- rt1.L SP-4
0.0 40.0
PrSt
---- rt2.H OPI.H
200.0 100
rt2..L OP2.H
0.0 100
Company Standard settings are
shown in the lower display SP-H C-OP
100.0 0

Issue 3
SP-L A.PAS
0.0 0

IM/C250
SP-1 S.PAS
10.0 0
SP-2 Addr The Company’s policy is one of continuous product
improvement and the right is reserved to modify the
20.0 1 information contained herein without notice.
© ABB 2001 Printed in UK (11.01)

ABB Ltd ABB Automation Inc

Howard Road, St. Neots 125 E. County Line Road
Cambridegshire, PE19 8EU Warminster, PA 18974 ABB has Sales & Customer Support expertise
UK USA in over 100 countries worldwide
Tel: +44 (0)1480 475 321 Tel: +1 215 674 6000
Fax: +44 (0)1480 470 787 Fax: +1 215-674 7183 www.abb.com
Customer Support CUSTOMER SETUP LOG 8

✍
ABB Ltd provides a comprehensive after
sales service via our Worldwide Service LEV4
Organization. Contact one of the following
offices for details of your nearest Service
PrFL
and Repair Centre. LEV3
SEtP Str1
United Kingdom LEV2 100.0
ABB Ltd LSPt
Tel: +44 (0)1480 475 321 tUnE End1
Fax: +44 (0)1480 470 787 LEV1 125.8
rYc1 200.0
OPEr rsPn
United States of America 5.0 rtE1
ABB Automation Inc. 145.8
Instrumentation Division cYc2 10.0
Tel: +1 215 674 6000 5.0 A1hP
Fax: +1 215 674 7183 800.0 SKt2
CodE 60.0
0 HYSt
Client Warranty 0.1 A2hP
200.0 End3
Prior to installation, the equipment referred to in this manual must be stored in a Correct 100.0
clean, dry environment, in accordance with the Company's published specification. password Pb-h
100.0 rAtO
Periodic checks must be made on the equipment's condition. rtE3
AtnE 1.000
In the event of a failure under warranty, the following documentation must be 20.0
provided as substantiation: OFF Pb-c
100.0 bIAS
1. A listing evidencing process operation and alarm logs at time of failure. 0.0 SKt4
2. Copies of operating and maintenance records relating to the alleged faulty unit. Intr 30.0
30 rrtE
OFF SSSP
rSEt YES
50.0 OAdJ
0.3 PHYS
drIV YES
1.0 rPt5
OLAP 0
0.0 Company Standard settings are
shown in the lower display

Instrument Serial Number:

Product Code: C 250 / /

 CUSTOMER CONFIGURATION LOG

LEV5
CnFG
LEV6
CnFG
EnGH
✍
100.0
AbCd
---- EnGL
0.0
EFGH
---- rt1.H SP-3
100.0 30.0
JKLn
---- rt1.L SP-4
0.0 40.0
PrSt
---- rt2.H OPI.H
200.0 100
rt2..L OP2.H
0.0 100
Company Standard settings are
shown in the lower display SP-H C-OP
100.0 0

Issue 3
SP-L A.PAS
0.0 0

IM/C250
SP-1 S.PAS
10.0 0
SP-2 Addr The Company’s policy is one of continuous product
improvement and the right is reserved to modify the
20.0 1 information contained herein without notice.
© ABB 2001 Printed in UK (11.01)

ABB Ltd ABB Automation Inc

Howard Road, St. Neots 125 E. County Line Road
Cambridegshire, PE19 8EU Warminster, PA 18974 ABB has Sales & Customer Support expertise
UK USA in over 100 countries worldwide
Tel: +44 (0)1480 475 321 Tel: +1 215 674 6000
Fax: +44 (0)1480 470 787 Fax: +1 215-674 7183 www.abb.com
 Series 9000
RESEARCH® CONTROL Installation &
Valves Operation Manual

BadgerMeter,Inc. 940467
1-02
®
 TABLE OF CONTENTS

Page
General --------------------------------------------------------------------------------------------------------------6-1
Installation --------------------------------------------------------------------------------------------------------- 6-1
Disassembly and Reassembly ------------------------------------------------------------------------------ 6-1
Replacing Trim Sets -------------------------------------------------------------------------------------------- 6-1
Installing Trim Sets --------------------------------------------------------------------------------------------- 6-2
Lapping Sequence ---------------------------------------------------------------------------------------------- 6-3
Assembly -----------------------------------------------------------------------------------------------------------6-3
Stroke Adjustment and Pressure Test --------------------------------------------------------------------6-4
Packing, Chevron Ring ---------------------------------------------------------------------------------------- 6-5
Braided Teflon and Graphoil Packing -------------------------------------------------------------------- 6-5
Bellows --------------------------------------------------------------------------------------------------------------6-7
General ----------------------------------------------------------------------------------------------------------6-7
Removal of Assembly from Valve ----------------------------------------------------------------------6-7
Removing Innervalve from Bellows Assembly & Seat from Body -------------------------- 6-8
Installing Bellows Seal Assembly, Intervalve & Seat --------------------------------------------6-8
Valve Positioner --------------------------------------------------------------------------------------------------6-9
General ----------------------------------------------------------------------------------------------------------6-9
Integral Mounting --------------------------------------------------------------------------------------------6-9
Range Springs ------------------------------------------------------------------------------------------------6-9
Top Loading, Air-to-Close -------------------------------------------------------------------------------- 6-9
Bottom Loading, Air-to-Open ----------------------------------------------------------------------------6-10
Adjusting Zero ------------------------------------------------------------------------------------------------6-10
Servicing ------------------------------------------------------------------------------------------------------- 6-10
Terminology ------------------------------------------------------------------------------------------------------- 6-11
Notes -----------------------------------------------------------------------------------------------------------------6-12
Special Information --------------------------------------------------------------------------------------------- 6-13
General

The purpose of these instructions is to supply pertinent to hold unbalance created by higher pressure on actual
information for installation of original equipment, repair, application. It should be noted that on air-to-close valves
adjustments, retrimming, repacking and other informa- with no pressure, the travel indicator will show over travel.
tion necessary to achieve the best possible service With 3 PSIG to actuator, the indicator will be very close
from Research Control Valves. to the open position.

Research Control Valves are engineered, designed, and Disassembly and Reassembly
manufactured with the end user in mind. Most parts are
interchangeable with any other like assembly. The inner (Best done at instrument shop bench)
components (spare trims) are available in 39 different
flow coefficient (Cv) sizes and in many different mate- For the purpose of these instructions, consider the
rials compatible with most process conditions. topworks or actuator as a complete sub-assembly not
to be dismantled except for replacing diaphragms or
Installation topworks packing. The only necessary topworks ad-
justment is made with the spring adjuster and/or the
After inspecting the valve (or valves) and determining zero adjustment on positioner-equipped valves (see
that the valve (or valves) meets the specifications, in- paragraph on Positioners). To position the stem, travel
stall as follows: in relation to the 3-15, 3-9, 9-15 PSIG etc. instrument
signal operating the valve.
1. Normal installation is directly into any 1/4", 1/2",
3/4", or 1” piping system with flow direction arrow on Replacing Trim Sets
body pointing downstream. This allows the stem pack-
ing to see the lowest pressure conditions after the Installing innervalve trim sets is accomplished with the
pressure drop occurs. It should be noted that chevron body and bonnet subassembly separated from the
ring stem packing is a dynamic seal that needs pres- topworks using appropriate wrenches. (Tool kits are
sure to be energized. available at a nominal cost for 1/4”, 1/2”, 3/4”, and 1”
valves.) To separate the body bonnet assembly from
2. Valves, especially plastic, should be bracket mounted the topworks on ATO valves, apply 6-9 PSIG instru-
in high vibration areas or where they may be subjected ment air to the operator, lifting innervalve off seat to
to damage from shock. If necessary, provide as required, prevent damage to the valve seating surfaces. (Not
bypass, manual block valve, filters, etc. When install- necessary for ATC valves.)
ing valves that have the Low Flow “P” Series innervalves,
small micron filters should be used where process per-
mits.

3. Connect instrument air supply to diaphragm case

using appropriate NPT fittings (1/8" NPT for 1/4" valves
and 1/4" NPT for 1/2", 3/4", and 1” valves) to the de-
sired tubing size adaptor (normally 1/4” tube fittings).
All connections to standard positioners, Moore prod-
ucts or Badger®, are 1/4" NPT. (For positioner data, see
paragraph under Positioners.)

4. All standard production valves as shipped are ad-

justed and preset at the factory with 90 PSIG air piped
to the inlet port of the body. Air-to-open valves are ad-
justed to come off seat at approximately 3.25 PSIG
instrument signal and be fully opened at 15 PSIG. Air-
to-close valves are set to close when signal is at 14.75
PSIG and be fully open at 3 PSIG. Process conditions
may dictate additional adjustment of the spring adjuster

FIG. 1

1
1 .With innervalve off seat, use two open-end wrenches Installing Trim Sets
(1/4" for 1/4" valves and 3/8" for 1/2", 3/4", and 1”
valves), one holding the stem connector in position, (Matching pairs do not separate)
and with the other loosen the topworks stem nut above
travel pointer; remove travel pointer. With all parts cleaned in an appropriate solvent, install
desired trim set in body bonnet assembly as follows:
2. With valve body in vise (clamp on ends), loosen the
yoke to bonnet locknut (yoke locknut) with a slotted
end wrench (7/8" boxed end for 1/4" valves, 1-1/8" for
1/2", 3/4" and 1" valves), and unscrew completely.

3. With the open-end wrench, turn the stem connector

counterclockwise (right hand threads), unscrewing from
the topworks stem completely. (Fig. 1)

4. Remove topworks from body bonnet assembly.

5. With the valve body in vise, loosen and unscrew

bonnet from body using open-end or crescent wrench.

FIG. 3
1. With trim as shown in Figure 3, apply a coating of
Neolube (graphite dry film lubricant), process permitting,
to the threads and seating surfaces of the seat. Air dry
for 30 seconds. Do not use any thread sealing
compounds containing metal particles. NOTE: New
replacement innervalves, come pre-coated with NeoLube
except those specially cleaned.

2. Remove seat from innervalve and place hex first into

FIG. 2 the long set socket wrench and T-handle assembly.
NOTE: Tissue paper can be stuffed into the socket to
6. Remove seat from body using a deep thin wall socket prevent seat from falling through.
and T-handle assembly (3/8" hexagon for 1/4" valves,
5/8" hexagon for 1/2", 3/4" hexagon for 3/4"valves, and
15/16" hexagon for 1” valves).
Some purchased long set sockets
(heavyduty) will not fit body cavity without turning
O.D. to fit past body threads.
(Fig. 2)

7. Most standard innervalves “K” through “P18” in 1/4"

valves and “F” through the “P” series trim in 1/2" valves
can be removed upward from the bonnet through the
packing, all others by removing stem connector and
withdrawing downward through the packing. When
removing the larger trims down through packing, it is
best to withdraw stems until threaded portion is in
contact with packing and then rotate stem and allow FIG. 4
the threads to screw through the packing area.
3. With body inverted in palm of hand as shown in
Figure 4, start seat threads into body, invert body and
tighten seat. Do not over-torque. Standard torque figures
using new parts at the factory are: 10/11 ft/pounds on
“P” trim seats, 8.5 ft/pounds on other 1/4" seats, 35 ft/
pounds on 1/2", 3/4" and 1” seats. It should be noted
that torque figures are applicable to new parts and may
not be the same for used parts. For longest service life,
on new or used parts, it’s best to use procedure detailed
in paragraph 4.
2
4. Torque seat firmly into body with the short T- handle
assembly. Check seat to body seal, by making body a
bubble chamber, using a pointed plastic plug in seat to
seal as shown in Figure 5 with downstream port plugged
and 50 psi air pressure upstream, check for leak. If
leak exists, re-torque seat and recheck until bubble-
tight seal is accomplished. On smaller letter or “P” series
trim sets, over-torquing seat in the body can reduce the
orifice size to where interference between innervalve
and seat can cause a premature mechanical failure
(galling) when stroking valve.

FIG. 6

clockwise, counterclockwise motion between the thumb

and forefinger, lifting the innervalve off seat and
repositioning periodically to achieve a uniform lap ring.
After each lapping operation, remove bonnet from body
and clean innervalve and seat from body. Clean seat by
submerging body in solvent and swabbing orifice with
wetted pipe cleaner and blow dry with air. After cleaning,
reassemble and check leak rate as shown in Figure 7.
Caution should be taken to not overlap.

FIG. 5

5. With body in vise, again clamping across ends of

body not sides of body, place body bonnet gasket in
place. (Process permitting, coat each side of gasket
with lubricant such as Dow Corning or Dupont Krytox
valve seal.) With the stem section of the trim set
installed in the bonnet, coat the bonnet threads (body
end) with lubricant.

6. Screw bonnet into body and tighten with open-end or

crescent wrench. Apply the proper torque to bonnet/
body joint as listed on the back side of individual
technical briefs. FIG. 7

Lapping Sequence
7. Stroke innervalve manually to check for misalign-
ment. Should misalignment exist, check straightness Lap for about 30 seconds, clean and check leak rate;
of innervalve or packing. (See Packing Installation.) repeat sequence until desired shutoff is achieved. If
after lapping three or four times leak still exists, check
NOTE: All replacement trim sets have been prelapped the seating surfaces of both innervalve and seat for
at the factory. When installed per instructions, trims excess nicks, scratches, or indication of galling if the
should leak no more than 1/10 of one percent of trim has previously been in service. Do not lap for
maximum flow for the given size, (ANSI Class III). If shutoff any of the “P” series trims.
necessary, with care, bubble-tight shutoff can normally
be achieved by lapping in seating surfaces with the Assembly
innervalve set installed in the body bonnet assembly
using lapping compound (white aluminum oxide 38-1000 1. With body in vise, place topworks yoke on bonnet
grit) with the packing removed, using the packing glands with yoke locknut slipped over the stem connector and
as the upper guide (brass lap bushing available at down on bonnet threads (6-9 PSIG air on air-to-open
factory). See Figure 6. Lapping should be done with a topworks).

2. With topworks in correct position relative to the

centerline of the body, tighten yoke locknut using a
boxed-end (slotted) wrench.
3
3. Raise innervalve and screw the stem connector on valve open. Using a plastic squeeze bottle filled with a
topworks stem until the two stems are butted together. soapy water solution, flood each joint and inspect for
leaks. Check and tighten packing just until no leak is
4. Install travel pointer between stem connector and visible. Do not over-tighten. (Fig. 9)
locknut on topworks stem. Hold stem connector in place
and tighten topworks stem nut against the travel pointer
positioned 1/32" to 1/16" away from travel scale.

Stroke Adjustment and Pressure Test

1. With valve completely assembled and with a manually

regulated supply (3-15 PSIG) to the topworks, adjust
with spring adjuster until valve stroke is corresponding
to the normal 3-15 PSIG instrument signal. To set this
precisely, pipe 90 PSIG air to the upstream port and
with rubber tubing piped from downstream port, bubble
check shutoff point. (Fig. 8)

2. Set air-to-open valves to open at 3-1/4" PSIG.

FIG. 9

7. Normal hysteresis (dead band) in valve stroke should

be no more than 1/4 PSIG instrument signal. This can
be checked by placing the thumb and forefinger on the
valve stem in contact with the packing gland and
regulating manually the 3-15 PSIG instrument signal
(gauge in line), visually watching gauge and feeling
movement. (Fig. 10)

FIG. 8
3. Set air-to-close valves to close at 14-3/4" PSIG.

4. Nominal stem travel of 7/16" for 1/4" valves and

9/16" for 1/2", 3/4", and 1” valves is fixed in the topworks
spring rate for a 12 PSIG span. If valve has been set
with a high bench setting because of pressure, full travel
may not occur at 15 PSIG.

5. If necessary, reposition travel scale relative to stroke.

6. Pressure test all seals with 90 PSIG air piped to the

upstream port, downstream port plugged with

FIG. 10

4
Packing, Chevron Ring psi). If packing leaks, tighten gland just until leak stops.
Excess torque can damage Teflon components. Once
1. Proceed with disassembly of body-bonnet assem- this procedure is complete, the valve can be tested at
bly as in changing trims. higher pressures.
CAUTION: Do not tighten gland more than is necessary
2. Remove the packing gland and all components from to stop leaks.
within the cavity. If the Teflon packing follower has been
damaged due to over tightening and extruded into the NOTE: On valves supplied prior to October 1993, the
threads of the packing cavity, a standard screwdriver packing follower on all valves was virgin Teflon and
can be driven into the teflon to unscrew the follower. ln packing adaptor was the same metal material as valve.
this case, the packing follower needs to be replaced. To improve on the total packing function in regard to
sealing and replacement, both the follower and adaptor
3. Clean and inspect cavity and parts for damage. materials have been changed to now available, Teflon
PFA. This denser Teflon material allows the guide
4. Place packing adaptor in the cavity making sure the diameter to be closer for better alignment and solves
flat side is down and in place. the cold flow problem of the original virgin Teflon follower.

5. Place the first ring into the cavity at a 90 degree

angle to its seated position. When the ring is at the
bottom of the cavity, tip it over with the cup side down
using a small plastic or wooden probe. Continue this
procedure with the two additional rings. This method
prevents the threads of the cavity from damaging the Braided Teflon and Graphoil
lips of the rings.
The original packing for Research Control Valves was
6. Place the packing follower on top of the rings, making braided Teflon which used a smaller gland nut. After
sure the inverted “V” is down. (The arrangement for molded chevron rings became available and for a period
reversed Cv ring vacuum packing requires special parts.) of time, there was a difference between the bonnet
packing cavity, depending on type of packing used. The
7. Replace the packing gland. Tighten until contact is components parts were not interchangeable until the
made with the packing follower. current design was introduced in 1972, standard 1981,
using a common cavity for all types packing.
8. If the plug portion of the trim is machined integral on
the stem, the stem connector should be tightened onto 1. Braided Teflon is available and used in current packing
the stem before insertion into the bonnet and may be cavity by putting in a dummy stem to fit the packing
inserted through the packing from the top of the bonnet. over as shown in Figure 11. Fill the cavity
If the plug portion of the trim is screwed onto the stem,
the stem should be placed through the packing from
the bottom of the bonnet by gently screwing the stem
threads through the packing. The stem connector can
then be tightened onto the stem.

9. Retract the stem sufficiently to keep the trim from

seating and screw the bonnet into the body. Be sure to
install gasket.

10. Apply the proper torque to bonnet/body joint as listed FIG. 11

on the back side of individual technical briefs under with sock or rope type packing, tamping into the cavity
pressure/temperature ratings. with a packing tool or piece of appropriate size copper
tubing as shown in Figure 12, until cavity is full with a
11. Proceed with assembly and adjustments per Page couple threads showing. Screw gland in and tighten to
3. compress packing.

12. Test packing by tightening gland 1/4 turn past

fingertight. Do initial test with low pressure (80 to 100

5
 FIG. 12 FIG. 13

Remove gland and blow or pick out any small pieces 2. Graphoil Packing
that may be in the threads. (Fig. 13) Replace gland finger
tight and remove dummy stem Figure 14 and replace Depending on the application, graphoil packing is
with new innervalve and stem. Tighten packing gland available in preformed rings to fit standard packing
and test seal at final assembly the same as with chevron cavities for all Research Control Valves. When a process
ring packing. must run hot to prevent material from solidifying or for
other purposes where finned bonnets are used to
dissipate heat to protect the packing are not applicable,
graphoil may be the solution. If the application is quick
opening (on-off) and graphoil packing is used, the
standard actuator will work with higher operating pressure.
If application is to control, a positioner should be used
to overcome additional drag, or hysteresis, created by
graphoil making stem seal, especially on high pressure
gases.

FIG. 14

6
Bellows

General bellows remains intact. Extreme care should be

exercised in removing and/or installing the Bellows Seal
On applications involving toxic gases, radioactive Assembly to preclude damage. The metal thickness of
materials and others where the primary seal at the valve the low pressure bellows is only 0.005” to 0.007” thick,
stem is critical, a metal bellows stem seal can be used and excess torsion will twist and deform the convolutions,
to preclude leakage as long as the integrity of the damaging the assembly.

FIG. 15 FIG. 16

FIG. 17 FIG. 18

Removal of Assembly from Valve 2. On air-to-open valves apply air pressure to diaphragm
to raise innervalve off seat. (Not necessary for air-to -
1. Remove the valve from the process line and hold close valves).
valve in a bench vise clamped on the body ends.
7
3. Loosen stem connector locknut above travel indicator. NOTE: If the above procedure is being done because of
bellows failure, it is not necessary to be concerned
4. Loosen yoke nut holding topworks to bonnet. about damage to the bellows.

5. Rotate entire topworks counterclockwise; top-works Installing Bellows Seal Assembly, lnnervalve and
stem will unscrew from stem connector. Seat
CAUTION - Unscrew straight up or stem could be bent.
Generally the foregoing steps are the reverse of
6. Finish unscrewing yoke nut and lift off topworks. disassembly, but best results will be experienced by
processing in the following sequence:
7. Loosen and unscrew bonnet assembly from body.
(Fig. 16) 1. Screw innervalve into bellows assembly only hand
tight.
8. Loosen and unscrew bonnet cap and bellows
assembly from bonnet. (Fig. 17) 2. If the secondary packing in bonnet cap has not been
damaged, proceed; otherwise, remove old packing but
9. Grasp bonnet stem located immediately under do not replace until later.
connector with sharp nose pliers and remove connector
without allowing stem to turn. 3. Place bellows-bonnet gasket carefully over bellows
to flange.
10. Remove the bellows from the bonnet cap. At times
it is necessary to cut and fish out the Teflon bellows 4. Insert stem into bonnet cap, carefully turning in a
gasket in order to free up the bellows assembly for clockwise direction until flange is seated all the way
removal. into bonnet cap.

Removing lnnervalve from Bellows Assembly and 5. Be sure gasket is home and not damaged.
Seat from Body
6. With bellows upward, carefully screw bonnet into
1. Hold stem of bellows in a lathe collet or suitable bonnet cap by hand until it is seated.
holding device (1/8" for 1/4" valves or 3/16" for 1/2",
3/4", and 1” valves) and gently unscrew innervalve 7. Holding bonnet in a vise, screw bonnet cap home
counterclockwise using a small end wrench fitting the firmly with a wrench.
flats on the innervalve. Avoid any side motion or bending.
If the bellows stem threads unscrews before the 8. At this point install new secondary packing if
innervalve unscrews, make a strap wrench by cutting a necessary, tightening gland firmly by finger tight as with
strip of 80 grit emery paper the width of the bellows a standard packed valve. (See paragraph on packing.)
length and roll about three revolutions clockwise around
the bellows assembly with the coarse side against the 9. Remove from vise and hand-install connector by hand.
bellows. Grasp the emery paper by hand and with the
wrench on the innervalve flats, remove the innervalve 10. With small wrenches on connector and flats on the
from the bellows. Normally this procedure prevents innervalve, tighten firmly but prevent using any side
damaging the bellows because the emery paper wrapped motion.
around the bellows gives it more support transferring
the twisting forces to where the bellows is welded to 11. With body held in a vise as instructed, screw the
the lower end plate. bonnet, bellows seal and innervalve assembly into the
body.
2. Do not try to remove stem from bellows assembly.
12. When body bonnet assembly is complete, the
3. Do not grasp the bellows in any manner other than innervalve should be off seat with the bellows in its free
above nor allow it to twist. state and should move approximately 1/8" when pushed
down before touching seat.
4. Unscrew seat from body with a long set socket
wrench.

8
13. CAUTION - With valves having “P” trims, be sure two wrenches to tighten travel indicator lock nut to
the plug enters the seat before starting the bonnet preclude twisting the bellows. If the topworks is not in
threads into the body. the correct position with the stems butted together in
the middle of the connector, rotate the topworks
14. Assemble the topworks to the body-bonnet assembly counterclockwise to the correct position before locking
in the exact reverse order from dismantiling. On air-to down the stem locknut. Do not rotate more than 90°
open topworks remember to have air on the diaphragm,
rotating the topworks until the topworks and bellows 15. See stroke adjustment and pressure test.
stem butts together in the middle of the connector. Use

Valve Positioners

General

Badger’s valve positioners use the full force of the air

supply pressure to drive the diaphragm or piston of the
pneumatic actuator to a position corresponding to the
pneumatic instrument signal output from a controller
(pressure, temperature, flow, etc.) and hold that position,
regardless of the forces which tend to change valve
position.

Like all valve positioners, Badger’s have a feedback

circuit which measures position of the actuator’s
diaphragm or piston. The built-in valve positioner
supplies or vents air in response to the control-instrument
signal stroking the valve to the required position.

Integral Mounting

Badger’s compact valve positioners incorporate a single

axis force-balance principal of operation to insure
accurate and stable positioning of Research Control
Valves. The positioners become an integral part of the
valve actuator. In all cases, including bottom loading
applications, the built-in valve positioner is mounted
directly on the topworks with no external piping or other
exposed mechanisms.

Range Springs

The position of the diaphragm or piston in the valve

actuator is sensed by the amount of compressive force
exerted by the range spring on the valve actuator
diaphragm assembly. Standard strokes are 7/16" and Top Loading, Air-to-Close
9/16". Standard signal ranges are 3-15, 3-9, 9-15, and
6-30 PSIG. Consult the factory for other ranges. Air pressure from the control instrument is exerted
between the two lower diaphragms. Because of the
difference in the two diaphragm areas, the resultant force
is exerted in an upward direction. In balance condition,
the pneumatic force on the diaphragm plus

9
the upward force exerted by the range spring is balanced ATO valves with type BLRA or Moore 73B positioners,
by the downward force of the zero adjustment spring. In zero adjustment is made with 3 psi instrument air to the
balance condition, positioner vents to atmosphere. positioner, turning zero adjustment screw until valve
seats at 3 psi. Full travel within tolerances governed by
When control-instrument pressure increases, the the range spring should occur on ATO or ATC valves
diaphragm assembly will move upward closing the using the standard 3-15, 3-9, 9-15, etc. instrument signal.
exhaust port and opening the pilot valve allowing supply
air to pass directly to the actuator diaphragm. The supply NOTE: Factory zero adjustments are made on Research
air will drive the actuator downward. As the actuator Control Valves with positioners, using 90 PSIG air
moves down, the range spring relaxes until its force pressure piped to the upstream valve port, connecting
decreases enough to offset the increase in control- a Tygon or rubber tubing to the downstream port and
instrument pressure, allowing the pilot valve to close immersing the end in a water filled container to detect
and exhaust to open. On air-to-close valves with any leakage across the seat during zero adjustment.
positioners, the supply pressure should be sufficient
for function, but never excessive. For function the Servicing
positioner supply pressure needs to be a minimum of 3
PSIG above instrument signal. Excessive supply Badger’s valve positioners must be isolated from the
pressure can result in damage to trims when the system before service or removal can be accomplished.
innervalve touches the seat and the signal continues (Recommended procedure is to move complete valve
down. The positioner sees this as resistance and reacts, with positioner to instrument repair bench where
causing the full supply pressure to be applied to the necessary tools and manual set air regulators are
main diaphragm in the actuator. available.)

Bottom Loading, Air-to-Open To clean pilot or spool valve, remove brass hex head
sealing screw under top cap and with small sharp nose
Air pressure from control instrument is inserted between pliers, tweezers or other device, remove and clean pilot
the dual upper diaphragms and the center diaphragm. or spool valve and replace. On air-to-close TLDA and
Because of the difference in the two diaphragm areas, Moore 73N positioners, the pilot is a one piece unit that
the resultant force is exerted in a downward direction. seldom fails due to dirty air or material such as Teflon
In balance condition, the pneumatic force on the tape getting into the pilot and causing malfunction. On
diaphragm, plus the downward force exerted by the zero air-to-open BLRA and Moore 73B positioners, the
adjustment spring, is balanced by the upward force of functional clearances around the spool valve is very
the range spring. In balance condition, positioner vents close and more likely to fail due to dirty air or Teflon
to atmosphere. tape. Clearance is a function of bleed and must be close
as possible, but large enough to function. To replace
When control-instrument pressure increases, the the diaphragm assembly, it is necessary to unscrew
diaphragm assembly will move downward allowing the the six screws holding the positioner to the adaptor and
spool valve to close the exhaust port and allow the remove the positioner assemble. Invert positioner and
supply air to pass through interior porting to the bottom remove the two assembly screws in the bottom ring.
side of the diaphragm or piston in the actuator. The When assembling the positioner diaphragm assembly
supply air will drive the actuator upward. As the actuator to the main housing, make sure to align index grooves.
moves up, the range spring will compress until its force
increases enough to offset the increase in control- Positioners must be correctly assembled in order to
instrument pressure causing the spool valve to move, function. Individual sub-assemblies such as the
shutting off supply air to the actuator and opening diaphragm assembly should be replaced as one unit.
exhaust.

Adjusting Zero

For ATC valves with type TLDA or Moore 73N12F

positioners, zero adjustment is made with 15 psi
instrument air (for 12 psi span) to the positioner, turning
zero adjustment screw until valve seats at 15 psi. For

10
TERMINOLOGY

PCV - Pressure Control Valve

LCV - Level Control Valve
TCV - Temperature Control Valve
FCV - Flow Control Valve
Topworks (Actuator) - The assembly that provides force
Positioner - Instrument added or attached to topworks for more precise control
ATO - Air to Open. Increasing air signal opens valve
ATC - Air to Close. Increasing air signal closes valve
F/O - (Fail Open) Valve opens on air failure
N/O - (Normally Open) Valve opens on air failure
F/C - (Fail Close) Valve closes on air failure
N/C - (Normally Close) Valve closes on air failure
Body Bonnet Assy - That assembly consisting of body, bonnet, gasket, innervalve, stem, seat, packing,
gland and yoke nut
Trim Set - The interchangeable components in a set consisting of innervalve, stem and seat
=% - Equal Percentage. Lift versus flow characteristic
Lin. - Linear lift versus flow characteristics
Q.O. - Opening - ON-OFF service
P1 - lnlet pressure to valve
P2 - Downstream pressure from valve
HP - Delta P - Pressure drop across valve
Cv - Flow Coefficient - Water flow at 1 PSI pressure drop
Chevron Rings - Packing, molded V-rings (normally 3 per set)
Braid Tef. - Packing, rope-type braided Teflon with Teflon suspensoid lubricant

11
Notes

12
Special Information
Use this page for recording special operator information not included in the preceding (i.e., internal and supplier phone
numbers, addreses, etc.)

13
 Due to continuous research, product improvements and enhancements,
Badger Meter reserves the right to change product or system specifications
without notice, except to the extent an outstanding bid obligation exists.
Please see our website at
www.badgermeter.com
for specific contacts. BadgerMeter,Inc.
6116 E. 15th Street, Tulsa, Oklahoma 74112
(918) 836-8411 / Fax: (918) 832-9962
Copyright © Badger Meter, Inc. 2002. All rights reserved, all data subject to change without notice. ® www.badgermeter.com