Neuenhauser Kompressorenbau GmbH

Department: pressure equipment

Hans-Voshaar-Str. 5
D-49828 Neuenhaus
Germany
Tel.: +49 5941 604 –0
Fax: +49 5941 604-202
Email: [email protected]
www.neuenhauser.de / www.nk-air.com
prepared 19.07.2016

Please read these operating instructions carefully in order to ensure safe

operation and store them for further use!
 Operating Instructions – Pressure Equipment and Accessories

6.9 Opening under pressure .............................................................................. 28

Table of contents 6.10 Recurring inspections................................................................................... 28
1 Preface ................................................................................................................... 2 6.11 Corrosion, Wear ........................................................................................... 29

2 Safety notes, dangers .......................................................................................... 3 6.12 Troubleshooting ........................................................................................... 30

6.13 Repair work on the valve head .................................................................... 33
3 Description of the symbols used ........................................................................ 5
6.14 Gasket sets .................................................................................................. 41
4 NK pressure equipment ....................................................................................... 6
6.15 List of tools ................................................................................................... 41
4.1 Description / design of the pressure equipment ............................................. 6
7 Guarantee ........................................................................................................... 42
4.2 Range of application, working method ........................................................... 7
8 Spare parts, Customer service ......................................................................... 43
4.3 Setup of the pressure equipment, technical data ........................................... 7
4.4 Design Characteristics.................................................................................... 8 9 Appendix ............................................................................................................. 44

5 Equipment, Valves, Fittings, Accessories ....................................................... 11

These operating instructions can be requested in PDF format from
5.1 Valve heads .................................................................................................. 11 [email protected]!
5.2 Exceeding the permissible operating pressure ............................................ 17
5.3 Drainage ....................................................................................................... 21

6
5.4 Pressure indicator ......................................................................................... 22
Handling notes .................................................................................................... 22
6.1 Transport and storage .................................................................................. 22
Note
i
Reprinting of the text and diagrams and drawings, also
6.2 Checking on delivery .................................................................................... 23
6.3 Set up at the operating location .................................................................... 24
in parts, is not permitted!
6.4 Assembly instructions ................................................................................... 25
6.5 Operation ...................................................................................................... 25
Revision Description Date created by
6.6 Testing of the set up ..................................................................................... 26 17 Complete revision, new design 19.07.2016 Wegner,Tim
6.7 Maintenance, Upkeep and Inspection .......................................................... 27
6.8 Inspection ..................................................................................................... 27

© Neuenhauser Kompressorenbau GmbH Page 1 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

1 Preface any time.

NEUENHAUSER KOMPRESSORENBAU GMBH will not be held liable for the content, and for
We are pleased that you have purchased a pressure equipment of the Neuenhauser
individual statements in documents of third party manufacturers and sub-suppliers, in
Kompressorenbau GmbH.
so far as they are part of these operating instructions or are added to them.
These operating instructions are intended to:
Corrections, suggestions for improvement and other suggestions for the operating
- provide the operator with the required knowledge concerning structure, function
instructions are welcome at any time.
and way of operation of the pressure equipment.
- to serve as instructions on how to operate the pressure equipment appropriately
Apart from this, NEUENHAUSER KOMPRESSORENBAU GMBH notes that the old pressure
and safely.
equipment directive 97/23/EC was replaced by the new directive 2014/68/EU as of 19
- to warn of dangers and point out the required safety and protective measures.
July 2016.
- help the operator to prevent faults and rectify them where appropriate.
The operating instructions are binding for transport, storage, assembly, commission-
ing, operation, maintenance and repair.
If difficulties should occur which cannot be solved with the help of the operating
instructions, further information must be requested / obtained from the manu-
facturer.
The operator must ensure that these operating instructions are read carefully by his
i
IMPORTANT!
operating, maintenance and assembly personnel. The notes and warnings, particularly The contents do not claim to be complete. General technical knowl-
the safety regulations must be followed in all details. edge is a pre-requisite.
All people who are entrusted with setting up, installation, assembly, handling, commis-
sioning, operation and maintenance of the pressure equipment must have qualifica-
tions relevant for their activity and job.
The pressure equipment and components are manufactured and issued in accordance
with the relevant German, European and international standards, regulations and
complex of rules.
i
IMPORTANT!
For the set-up, commissioning, operation and repeat tests, the respective national The operator must indicate and check operating conditions which
regulations are to be observed as well. are special or deviant and implement these accordingly!
When using the pressure equipment abroad and in plants with special regulations
(e.g. nuclear plants, large scale chemical plants, ships and other vehicles,...), the rele-
vant standards are to be indicated and checked by the operating company and to be
implemented accordingly.
The manufacturer reserves all rights to make technical changes and improvements at

© Neuenhauser Kompressorenbau GmbH Page 2 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

2 Safety notes, dangers measures are adhered to during all tasks.

The safety conditions stipulated by the inspection bodies must be adhered to. Regula-
Danger to persons and objects from the pressure equipment can result from incorrect
tions of the countries and regional, local and company regulations which are applica-
use, inappropriate treatment and non-adherence to the safety regulations.
ble for the plant and place of installation must be observed.
Potentially dangerous occurrences include:
- sudden release of energy stored in the appliance through failure of pressure bear-
ing walls, bursting of the equipment, chemical reactions, explosion
- Escape or spraying out of liquids or gases at high pressure or high temperature.
- Thermal danger due to high temperatures
- Danger due to noise, sudden escape of compressed air, banging noises
i
IMPORTANT!
The operator must observe the following regulations in particular:
- DGRL 2014/68/EU

i
IMPORTANT!
- Product Safety Act (ProdSG)
- Regulations on safety and health protection for the provision of
work equipment (German Health and Safety at Work Regula-
tions - BetrSichV)
In principle the following applies to all work on the pressure equip- - Fourteenth regulation pertaining to the Product Safety Act
ment: (Pressure Equipment Ordinance – 14. ProdSV)
- Remove air from pressure equipment (make free of pressure). - Technical Rules for Operating Safety (TRBS)
- Depressurise all pipes and pressure chambers on the pressure especially 1201, 1203, 2141
equipment and valves and fittings. - Industrial safety regulations
- Secure compressed air supply against unauthorised switching - Accident Prevention Measures (UVV)
on and affix repair notice. - Association of Industrial Trade Associations-Regulations BG
- Apply safety devices before commissioning. regulations (such as DGUV regulation 1, DGUV regulation 9)
The highlighted presentation in the operating instructions draws particular attention to - Industrial Safety Act (ArbSchG)
the dangers, risks and safety related information.
These instructions must be rigorously followed!
If a statement in the operating instructions does not correspond to the specifications
required locally, the stricter version is to be applied.
In addition to the operating instructions, the regulations applicable for the oper- In addition the operator is responsible for his employees having the necessary qualifi-
ating company and place of installation as well as the respective regulations of cations, for instruction on the pressure equipment / the apparatus and also for knowl-
the inspection company must be adhered to. edge of the potential danger and the operating instructions.
The operator must ensure that the legal health and safety and accident prevention

© Neuenhauser Kompressorenbau GmbH Page 3 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Prescribed safety wear and safety equipment (PSA) is to be provided by the operator.
Its use and the compliance with other protective and safety measures are to be moni-
tored by the operator.
The regulations of the German Water Management Act, DGUV provision 1 as well as
the safety data sheets of the respective manufacturer are to be strictly adhered to
when handling hazardous liquids and materials which may be harmful to ground wa-
ter, e.g. lubricating oils or greases, solvents or cleaning agents and other chemicals.

© Neuenhauser Kompressorenbau GmbH Page 4 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

3 Description of the symbols used

! This sign is used when there is a threat of danger. Physical

and material damage are possible consequences.
Wear protective shoes / safety shoes

Warning about hanging load Use face protection

No entry for unauthorised persons Use eye protection

Prohibition sign (only in connection with addendum!) Use protective gloves

i Use protective helmet

Note
Emphasis on important notes and information
i
IMPORTANT!

General sign (only in connection with addendum) i

Note
No warning instructions or safety instructions are applied to the
equipment by the manufacturer! The required warning and instruc-
Use ear protection tion signs are to be attached to the apparatus by the operator in an
easily legible way!

© Neuenhauser Kompressorenbau GmbH Page 5 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

4 NK pressure equipment
4.1 Description / design of the pressure equipment
Pressure equipment from NEUENHAUSER KOMPRESSORENBAU GMBH usually is made
up of assemblies consisting of a compressed air tank with an installed valve head.
However, pressure equipment such as welding assemblies for control sections are
Vessels without supports / holders
also part of the product range.
The vessels can be delivered in different designs, sizes and dimensions up to 25000
litres and a maximum outer diameter of up to 3000 mm (depending on the wall thick-
ness). The respective valve heads are available in the nominal sizes DN 38, DN 50
and DN 80.
Additionally, the vessels are equipped with the corresponding inspection openings.
The NK standard pressure vessels with contents of 30 – 2500 l (ø324, ø480, ø650,
ø800, ø900) are operated at a pressure of 30 bar and equipped with valve heads in
Vessels with saddles Vessels with feet Vessels with claws
the nominal widths DN 38 and DN 50.

Deviating designs and special containers can be delivered on request and must Beyond the compressed air vessel, NEUEN-
be requested with the associated specification ([email protected]). HAUSER KOMPRESSORENBAU GMBH can also
Further examples, special designs and an overview of the entire product range of deliver complete modules, consisting of com-
Neuenhauser Kompressorenbau GmbH are presented in www.nk-air.de. pressor, compressed air vessel, necessary
tubing and further peripherals, from a single
4.1.1 Pressure vessels / modules source. The complete production and mounting
The NK standard vessels that are approved in the above dimensions with the common are performed in the production sites of
acceptance classes, are delivered without supports / holders. Therefore, the operator NEUENHAUSER KOMPRESSORENBAU GMBH.
on site is responsible for appropriately attaching/holding the containers with clamps or
similar devices. The design of these holders is also subject to the tasks of the opera-
tor. However, these can also be delivered, produced and delivered by NEUENHAUSER
KOMPRESSORENBAU GMBH.
Furthermore, these vessels can also be delivered with different versions for hold-
ing/set-up. Usually, these holders are designed as saddles, feet or claws. The follow-
ing table presents the different versions. If the site or purpose of use requires any
different kind of holder/attachment, this can be done order- or project-specifically.
© Neuenhauser Kompressorenbau GmbH Page 6 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

4.1.2 Valve head nominal widths / NK special valve / accessories 4.2 Range of application, working method

The valve heads of NEUENHAUSER KOMPRESSORENBAU GMBH are all own productions Starting air/compressed air vessels are used to store compressed air and therefore
and are assembled in parallel to the vessel production. The following nominal widths energy. This storage volume is built up by the compressors and needed, e.g., to start
are part of the product range and available ex stock at all times: large diesel and gas engines as well as gas turbines or for working and instrument air
applications. The areas of application include marine propulsion, pump gear, power
DN 38 DN 50 DN 80 generation on ships and oil rigs as well as diesel and gas power stations, block heat
and power plants and emergency backup generators.

The application area of the vessel and valves and fittings is the responsibility of the
system planner / operator.

4.3 Setup of the pressure equipment, technical data

Basic body:
The standard pressure vessel consists of one pressure space and is made up as fol-
lows:
In addition to the valve heads, a special valve is - Rolled and longitudinally welded jacket sheet or seamless jacket tube
available from NEUENHAUSER KOMPRESSORENBAU - Two curved (basket arch) bottoms
GMBH. This is an angular valve that can be exe-
with the following connections:
cuted in nominal widths DN 16 to DN 20. On the
- 1x block flange DN 100 or DN 200 at the front bottom for installation of the valve
inlet side, the valve is equipped with a G 1" outer
head (or, according to the rules or customer requirements on the side in the jacket)
diameter and on the outlet side with a G ¾“ inner
- 1x block flange DN 100 or DN 400 at the rear bottom (or on the side in the jacket),
thread. This corner valve is used, e.g., at the valve
which is closed with a lid. The lid contains a connection G 1.
head DN 80 as an auxiliary air or typhoon valve.
- or a 1x threaded socket G 1 in the rear (lower) bottom
- The block flanges are used for inner inspection of the pressure vessel.
- At least 1x threaded socket G 1 or G ½ in the rear end rim (drainage)
- at least 1x G 1 or G ½ in the front end rim for releasing air or for possible connec-
tion of further consumers
The drainage valve or the automatic drain (s. chap. 5.3) always must be installed con-
nected to the lowest point of a tank, so that the arising condensation can be com-
pletely discharged.

© Neuenhauser Kompressorenbau GmbH Page 7 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Connections which are not used are closed off with plugs or blind flanges. 4.4 Design Characteristics
4.4.1 Technical rules, European Directive

i
IMPORTANT!
Design, manufacture and testing of the pressure equipment conform to the corre-
sponding regulations, such as the Pressure Equipment Directive 2014/68/EU, the
AD2000 regulations and the relevant technical rules and standards.
It is not permissible to use the vessel in a way other than those pre-
scribed! The technical value limits indicated are always to be ad- To meet the pressure equipment directive, the conformity assessment is performed by
hered to! a notified body, such as the TÜV-Nord (e.g. modules B+F).
Vessels which are installed outside the area of application of the Pressure Equipment
The threads of the sockets and the connections in the lids and valve heads corre-
Directive, are to be certified according to the applicable regulations.
spond to ISO 228 and therefore are not self-sealing in connection with an associated
Pressure vessels for use on ships and off-/onshore units are manufactured and tested
closure screw (not conical). Sealing is achieved with a copper seal at the correspond-
in accordance with the regulations of the relevant classification society (hereinafter
ing thickness.
ship classification).
Additional and different connections (type and size) are possible following agreement.
The connections must be sized in design and number to meet the requirements of the 4.4.2 Design, materials
corresponding acceptance class.
NK standard vessels are generally designed for a max. permitted inner pressure of 33
Technically relevant data: bar (overpressure) and up to a max. temperature of +50 °C. The calculation takes
Materials: see chap. 4.4.2 place according to the AD2000 leaflets of the series “B“ for static operating method
Operating pressure: * without additional loads and/or based on the regulations for the required ship classifi-
Design pressure / max permissible pressure: * cation.
Max / min permissible temperature: *
The standard vessels correspond to the regulations of the common ship classifica-
Volumes: *
tions, such as Lloyd’s Register (LR), Bureau Veritas (BV), Det Norske Veritas - Ger-
Test pressure: *
manischer Lloyd (DNV-GL), American Bureau of Shipping (ABS), Russian Maritime
Process fluid: Compressed air; group 2- not hazard-
Register of Shipping (RS).
ous, art. 13, directive 2014/68/EU
Dimensions, diameter: s. project drawing, * The detailed design data are named in the approved drawing and are listed in
Weight: s. project drawing the associated project data sheet.
From case to case, order-related different pressures and temperatures may be
The data of the upper list that are applied with a * can be taken from the project data
specified. The values are given on the inspection certificate and the identifica-
sheet at the beginning of these operating instructions!
tion plate.

© Neuenhauser Kompressorenbau GmbH Page 8 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

The materials used are generally common and proven materials in pressure vessel sure fluctuation between pressure free condition and permissible operating pressure)
construction is N ≤ 1000.
("P" steels / pressure vessel steels). Corrosion, wear: see chapter 6.11
The materials for the vessel and also for the attached components which are supplied
4.4.4 Taking additional loads into account
such as flanges, covers, valves and fittings, bolts, connecting pieces and gaskets are
suitable for the operating conditions and media indicated on the rating plate. External loads:
The loads and tensions which occur do not exceed the permissible values. The mate- Reaction forces of carrying elements were not considered, and neither were reaction
rials and the coating are sufficiently resistant against the operating substance. forces from pipes and connecting loads.
Furthermore, loads such as traffic, wind, snow loads and exceptions such as earth-
Information on the weld seam execution, the welding process and the calculations and
quake, shock and vibration loads were not used as a basis for the design/calculation,
construction documents are listed in the internal documents / production documents of
since they are not known. Therefore, stability analysis regarding instabilities must be
NEUENHAUSER KOMPRESSORENBAU GMBH and are not passed on to external third par-
performed by the customer/operator or the above additional loads must be avoided!
ties. The designs meet the requirements of the above regulations. Additionally, the
We generally recommend tension-free installation!
corresponding audits and factory certifications are performed at regular intervals.
Additionally, a design of containers pursuant to other regulations (such as IRS, RRR,
KR, EAC, Brazilian No. 13, etc.) is possible as well upon separate request.

4.4.3 Working-life limiting construction characteristics

i
IMPORTANT!
Permissible load cycles: Alternating pressure loads of the pressure equipment at N>1000 are
The vessel was designed for mostly static operation and is permanently resis- not permitted!
tant at the pressure fluctuation width Δp ≤ 10% (N≤1000) of the permissible op-
erating pressure. Temperature:
A calculation for alternating loads with certain pressure fluctuation ranges and num- The vessel was designed for an operating and ambient temperature of 0 / +50 °C.
bers of load cycles during lifetime was not carried out. Temperature differences which have to be taken into account within the walls and
This mode of operation is not expected and not permitted for use as starting air between various receiver parts or sections do not occur.
receiver (storage vessel)! Additionally, the vessel must only be exposed to temperatures of ≤+0 °C (only in the
If operated with alternating loads, the operator must provide the appropriate informa- depressurised condition) when no condensate is in the vessel. This also is a reason
tion and have approvals carried out by the NEUENHAUSER KOMPRESSORENBAU GMBH why the vessel must be drained at regular intervals.
for the specific individual case (AD 2000 instruction leaflet HP 801 no. 15). This must The temperature range of the valves/fittings must be limited to +0 to +50 °C, to ensure
be indicated separately in the request. their tightness, function and safety. To comply with this temperature range, e.g. a
We refer you to AD instruction leaflet S1 (S2) for the delimitation between static housing in connection with a corresponding trace heating could be used here.
and alternating loads. The number of the start-up and close down processes (pres- Icing over of the valves/fittings must be avoided!
© Neuenhauser Kompressorenbau GmbH Page 9 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

4.4.5 Identification, information on the name-plate

The identification of the pressure vessel corresponds to AD 2000-leaflet A 401 and the
specifications of the common ship categories.
Information on the rating plate:
- Manufacturer: Neuenhauser Kompressorenbau GmbH
- Serial-no.:
- Date of manufacture:
- Nominal capacity:
- Design pressure:
- Test pressure:
- Design temperature:
- “CE“ identification of the notified body or certification number of the class

In addition the following data are stamped onto the block flange of the vessel:
- Serial number [__N_____ ]
- Design pressure: “WP [__]”
- Test pressure: “TP [__]”
- Date, inspection stamp: [Month] + [stamp of inspection company] + [year]
+ [certificate / test number of the inspection company]

© Neuenhauser Kompressorenbau GmbH Page 10 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5 Equipment, Valves, Fittings, Accessories tightness of the individual valves and the general strength are verified here. The ap-
propriate assembly and the pressure test and function tests carried out are certified
The pressure equipment usually consists of the compressed air tank, a mounted valve
with an inspection certificate EN 10204-3.1 of the manufacturer. Additionally, the trig-
head and a separately supplied drain valve/drain unit.
ger pressure of the safety valve is reviewed in the pressure test of the valve head. It
Additional accessories, valves and fittings etc. can be supplied if required.
must trigger/open at the latest at a tolerance of +/- 3% (according to DIN EN ISO
The AD 2000 regulations A 404, A 4 and the relevant chapters from the regula-
4126-1) or + 3% (e.g. purs. to DNV-GL Rules Ship Pt 4, Ch 7, Sec 5 – 2.2.8 …).
tions for the ship classifications are to be observed in particular for equipment
Additional inspection requirements can be agreed if requested.
parts of pressure vessels.
For components which are not manufactured by NK, operating instructions of
The valve head is marked with the permissible operating pressure and the permissible
the respective manufacturer will be provided.
temperature range, and it gets its own serial number which is independent of the ves-
sel. Additionally, every valve head is applied with a rating plate (chap. 4.4.5).
5.1 Valve heads
The compressed air receiver is supplied complete with mounted valve head. For spe- The medium compressed air is generally permitted for operation. Additionally,
cial vessels, in particular for vessels for the low-pressure area, it is possible that the the media water, water with air padding and nitrogen (only in coordination and
vessel is not equipped with a valve head, but that the fittings are directly connected to under observation of temperature, etc.) may be used as well. The permissible
the vessel (according to customer demand). limits indicated on the inspection certificate for pressure and temperature are to
Valve heads can be supplied in the nominal sizes DN 38, DN 50 and DN 80. be adhered to.
The valve head is bolted onto the block flange of the vessel with studs and nuts and
an intermediate gasket layer.

The shut off and safety controls are arranged centrally in a space saving way at a
valve block manifold.
The valves are operated by turning inwards and outwards by means of hand wheel.
By turning the hand wheel (right in a clockwise direction) the respective valve is closed
(cone-seat-function).
By using plastic materials for the valve seats, excellent sealing at low pressing is
guaranteed. The hand wheels are not designed to be impact hand-wheels.
The shut off valves do not have a non return valve function. The operator should fit Ventilkegel
valve cone
non return valves into the pipework if required in order to avoid reverse flows, reverse Ventilsitz
valve seat

currents or undesired flow directions.

Sectional view of valve head DN 38
Cone-seat-function
After completion of the valve head, it is subjected to a factory acceptance test. The

© Neuenhauser Kompressorenbau GmbH Page 11 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5.1.1 Valve head DN 38 - Pressure gauge shut off valve

Angular valve DN 8, PN 63 with G ½ male thread - G ¼ female thread (chap.
The valve head DN 38 is performed in accordance with DIN 6276. 6.13.12 / 9).
Operation: Open /close by hand wheel ø60.
All shut off valves are closed by turning the hand wheel right / in a clockwise The valve is bolted to the respective connection G ½ of the valve head. The USER
direction (cone-seat-function). is adjusted by use of correspondingly thick copper gasket rings.
The pressure gauge is attached to the connection G ¼ (internal thread).
The valve head DN 38 consists of the following fittings:
- Safety Valve
Basic form valve head DN 38 Form `B´ Two types can be chosen as standard:
- Type “Lorch 2108”
- Starting air valve DN 38for the starting air pipe to the motor / starter - Type “Leser 4383-H4”
Operation: Opening/closing by hand wheel ø160 (cone-seat function). On request it is possible to have different types of safety valve and / or other set
The complete valve inset DN 38 (chap. 6.13.1 / 9) and valve seat DN 38 (chap. / pressures and blow out performances. The safety valve is bolted at the connection
6.13.2 / 9) can be replaced. G ½ of the valve head. For further information on this topic, refer to chapter 5.2.
The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight- The safety valve may not be operated in a downwards facing position.
ened if required.
An discharge flange is mounted on the outlet of the starting air valve. The starting Options:
air pipe can either be bolted or welded into this oval flange. The maximal possible
bore in the outlet flange is ø 49 mm or G 1 ½. - Form `C´ with additional auxiliary air valve DN 8
The valve does not have a non-return (recoil inhibit) function. For design and function of the valve, see pressure gauge shut-off valve. The valve
is bolted across from this in the connection G ½ of the valve head.
- Filling valve DN 18 for the charging line from the compressor The valve does not have a non-return (recoil inhibit) function.
Operation: Opening/closing by hand wheel ø115 (cone-seat function).
The complete valve inset DN 18 (chap. 6.13.5 / 9) and valve seat DN 18 (chap. / - Form `A´ with drain valve on valve head
6.13.6 / 9) can be replaced. The drain takes place via a valve at the valve head and a pipe that reaches from
The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight- the valve head to the vessel bottom.
ened if required. Only possible in (vertically) standing vessels.
The filling pipe is connected at the connection G ¾ internal thread to the valve For design and function of the valve, see pressure gauge shut-off valve. The valve
head. is bolted across from this in the connection G ½ of the valve head. A stainless steel
The valve does not have a non-return (recoil inhibit) function. pipe is mounted onto the base side of the valve head with a compression joint.

© Neuenhauser Kompressorenbau GmbH Page 12 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

The pipe is sized so that the chamfered end reaches to the lowest point of the ves- Possible forms of the valve head DN 38
sel bottom. The difference in pressure ensures that the condensate is drained off Form
A AE B BE C CE
via the drainage pipe when the drain valve is opened. Valves
Starting air valve DN 38 X X X X X X
Note: The auxiliary air valve and the drain valve are mounted at the same connection Filling valve DN 18 X X X X X X
on the valve head block. It can be used only either as drain (form `A´ / `AE´) or auxil- Pressure gauge shut off
X X X X X X
iary air valve (form `C´ / `CE´)! A combination of both is not possible. valve
Safety Valve X X X X X X
- Form `AE´, `BE´, `CE´ with venting valve Drain valve X X
Freely blowing off shut off valve DN 8 following drawing Ve_30141 (chap. 9) with G Auxiliary air valve DN 8 X X
½ male thread and bores for the exit of compressed air. Air relief valve X X X
Operation: Open /close by hand wheel ø60.
The air relief valve serves to remove air from the starting air pipe. The con-
necting bore to the starting pipe is located behind (downstream) the starting air Pressure gauge shut off valve
valve. This means: When the starting air valve is closed there is no connection be-
tween the air relief valve and the vessel! Starting air valve DN 38
The air relief valve is therefore not intended for removing air from the vessel!

Filling valve DN 18
Note: Unoccupied connections at the valve head are closed with closure screws.

The operating signs at the valve head are designed in the English
Safety valves G 1/2
language by default. Other/deviating languages can be requested
(presentation of both
project-/order-relatedly! standard types)

Oval flange
Filling connection G ¾
(outlet)
(inlet)

Auxiliary air valve DN 8 (form `C´, `CE´) Air relief valve

Drain valve (form: `A´, `AE´) (form: `AE´, `BE´, `CE´)
© Neuenhauser Kompressorenbau GmbH Page 13 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5.1.2 Valve head DN 50 - Pressure gauge shut off valve

Angular valve DN 8, PN 63 with G ½ male thread - G ¼ female thread (chap.
All shut off valves are closed by turning the hand wheel right / in a clockwise 6.13.12 / 9).
direction (cone-seat-function). Operation: Open /close by hand wheel ø60.
The valve is bolted to the respective connection G ½ of the valve head. The USER
The valve head DN 50 consists of the following fittings: is adjusted by use of correspondingly thick copper gasket rings.
The pressure gauge is attached to the connection G ¼ (internal thread).
Basic form valve head DN 50 Form `D´
- Safety Valve
- Starting air valve DN 50for the starting air pipe to the motor / starter Two types can be chosen as standard:
Operation: Opening/closing by hand wheel ø160 (cone-seat function). - Type “Lorch 2108”
The complete valve inset DN 50 (chap. 6.13.3 / 9) and valve seat DN 50 (chap. / - Type “Leser 4383-H4”
6.13.4 / 9) can be replaced. On request it is possible to have different types of safety valve and / or other set
The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight- pressures. The safety valve is bolted at the connection G ½ of the valve head. For
ened if required. further information on this topic, refer to chapter 5.2.
An discharge flange is mounted on the outlet of the starting air valve. The starting The safety valve may not be operated in a downwards facing position.
air pipe can either be bolted or welded into this oval flange. The maximal possible
bore in the outlet flange is ø61 mm or G 2. Options:
The valve does not have a non-return (recoil inhibit) function.
- Form `A´, `B´ and `C´ with additional auxiliary air valve DN 12
- Filling valve DN 18 for the charging line from the compressor Auxiliary air/shut-off valve integrated in the valve head housing.
Operation: Open /close by hand wheel ø125. Operation: Opening/closing by hand wheel ø115 (cone-seat function).
A cone is pressed onto a valve seat via a spindle. The complete valve inset DN 12 (chap. 6.13.3 / 9) and valve seat DN 12 (chap. /
The complete valve inset DN 18 (chap. 6.13.5 / 9) and valve seat DN 18 (chap. 6.13.8 / 9) can be replaced.
6.13.6 / 9) can be replaced: The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight-
The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight- ened if required.
ened if required. The line for auxiliary air is connected to the associated connection G ½-inner
The filling pipe is connected at the connection G ¾ internal thread to the valve thread at the valve head.
head. The valve does not have a non-return (recoil inhibit) function.
The valve does not have a non-return (recoil inhibit) function.

© Neuenhauser Kompressorenbau GmbH Page 14 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

- Form `C´ with additional auxiliary air valve DN 8 Possible forms of the valve head DN 50
For design and function of the valve, see pressure gauge shut-off valve. The valve Form
A B C D
is bolted across from this in the connection G ½ of the valve head. Valves
The valve does not have a non-return (recoil inhibit) function. Starting air valve DN 50 X X X X
Filling valve DN 18 X X X X
- Form `A´ with drain valve on valve head Pressure gauge shut off
X X X X
The drain takes place via a valve at the valve head and a pipe that reaches from valve
the valve head to the vessel bottom. Safety Valve X X X X
Only possible in (vertically) standing vessels. Auxiliary air valve DN 12 X X X
For design and function of the valve, see pressure gauge shut-off valve. The valve Auxiliary air valve DN 8 X
is bolted across from this in the connection G ½ of the valve head. A stainless steel Drain valve X
pipe is mounted onto the base side of the valve head with a compression joint. The
pipe is sized so that the chamfered end reaches to the lowest point of the vessel
Pressure gauge shut off valve
bottom. The difference in pressure ensures that the condensate is drained off via Filling connection G ¾
the drainage pipe when the drain valve is opened. (inlet)
Starting air valve DN 50

Note: The auxiliary air valve and the drain valve are mounted at the same connection Filling valve DN 18
on the valve head housing. It can be used only either as drain (form `A´) or auxiliary
air valve (form `C´)! A combination of both is not possible.
Unoccupied connections at the valve head are closed with closure screws.

Auxiliary air valve DN 12

(form: `A´, `B´, `C´)

Safety valves G 1/2

The operating signs at the valve head are designed in the English (presentation of both
language by default. Other/deviating languages can be requested standard types)
project-/order-relatedly!

Oval flange
(outlet)
Filling connection G ½

Auxiliary air valve DN 8 (form: `C´) Drainage pipe

Drain valve (form: `A´) (form: `A´)
© Neuenhauser Kompressorenbau GmbH Page 15 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5.1.3 Valve head DN 80 - Pressure gauge shut off valve

Shut off valve PN 250 with G ½ male thread - G ½ female thread (chap. 6.13.12 /
All shut off valves are closed by turning the hand wheel right / in a clockwise 9). Design according to DIN 16271 with clamping socket and test peg M20x1.5. It
direction (cone-seat-function). is installed together with a shock reducer (G ½ - G ½).
Operation: Open /close by hand wheel ø60.
The valve head DN 80 consists of the following fittings: The shock reducer is bolted to the respective connection G ½ of the valve head.
The USER is adjusted by use of correspondingly thick copper gasket rings.
Basic form valve head DN 80 The pressure gauge is attached to the connection G ½ (internal thread).

- Starting air valve DN 80for the starting air pipe to the motor / starter - Safety Valve
Operation: Opening/closing by hand wheel ø280 (cone-seat function). Two types can be chosen as standard:
The complete valve inset DN 80 (chap. 6.13.9 / 9) and valve seat DN 80 (chap. / - Type “Lorch 2108”
6.13.10 / 9) can be replaced. - Type “Leser 4383-H4”
The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight- On request it is possible to have different types of safety valve and / or other set
ened if required. pressures. The safety valve is bolted at the connection G ½ of the valve head. For
A pre-welding flange N 80 is mounted on the outlet of the starting air valve. The further information on this topic, refer to chapter 5.2.
starting air pipe can either be bolted or welded into this pre-welding flange. This is The safety valve may not be operated in a downwards facing position.
designed according to standard EN 1092-1 and the parameters DN 80 and PN
63/64 and therefore has the connection sizes: ø88.9 x 3.6 mm. - Auxiliary air valve / typhoon valve DN 16 to DN 20 at most
The valve does not have a non-return (recoil inhibit) function. Angular valve DN 16 – DN 20, PN 42 with G 1 male thread - G ¾ female thread
(chap. 6.13.14 / 9). The valve can be supplied in the nominal sizes DN 16 up to DN
- Filling valve DN 38 for the charging line from the compressor 20.
Operation: Opening/closing by hand wheel ø160 (cone-seat function). Operation: Opening/closing by hand wheel ø115 (cone-seat function).
The complete valve inset DN 38 (chap. 6.13.1 / 9) and valve seat DN 38 (chap. / The complete valve inset DN 18 (chap. 6.13.5 / 9) and valve seat DN 18 (chap.
6.13.2 / 9) can be replaced. 6.13.6 / 6.13.8 / 9) can be replaced:
The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight- The valve spindle is sealed by a packing sleeve. The packing sleeve can be tight-
ened if required. ened if required. The valve is bolted to the respective connection G 1 of the valve
The filling pipe is connected at the connection G 1 ½ internal thread to the valve head. The USER is adjusted by use of correspondingly thick copper gasket rings.
head. This is delivered by default with a cutting ring screw connection for a pipe The line for auxiliary air or the typhoon is connected to the associated connection
outer diameter of 38 mm (or according to customer requirements). G ¾-inner thread at the valve.
The valve does not have a non-return (recoil inhibit) function. The valve does not have a non-return (recoil inhibit) function.

© Neuenhauser Kompressorenbau GmbH Page 16 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5.2 Exceeding the permissible operating pressure

The operating signs at the valve head are designed in the English
language by default. Other/deviating languages can be requested According to the AD 2000 regulations (A 2, A 403) and the regulations of the above
project-/order-relatedly! ship classifications, it must be prevented in any case that the vessel can be stressed
beyond the maximum permitted operating pressure.
Pre-welding flange DN 80
(outlet)

i
Starting air valve DN 80

Pressure gauge shut off valve IMPORTANT!

The set pressure of the safety valve may not exceed the maximum
Safety Valve
permissible operating pressure of the vessel!
(presentation of both
standard types)
Suitable measures for this may be:
- Control equipment and regulating installations on the compressor / pressure gen-
erator
- Pressure switch
- Safety Installations:
- Safety valves
- Bursting discs
- Limiters on the pressure generator
- Prevention of unauthorised temperatures and thermal expansion
- Monitoring installations, warning signals
- Pressure measurement and alarms

5.2.1 Safety valves

The vessel is to be equipped with a suitable safety valve prior to commission-
ing. If this has not been done by the supplier (NEUENHAUSER KOMPRESSORENBAU
GMBH), the operator is directly responsible for this!
Auxiliary air/typhoon valve
DN 16 - DN 20 When the set pressure is reached, the safety valve opens and blows the compressed
Auxiliary air/typhoon valve
air into the surrounding area. It must be ensured that the compressed air can blow-off
DN 16 - DN 20
Filling connection G 1 ½
without any danger (protection of individuals).
(inlet) The safety valve is mounted on the valve head by NEUENHAUSER KOMPRESSORENBAU
Filling valve DN 38
GMBH. For pressure vessels that are not equipped with a valve head, the safety valve

© Neuenhauser Kompressorenbau GmbH Page 17 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

is loosely enclosed and must be installed by the operator according to the information misadjustment/manipulation and must not be removed, since any claim to guarantee
in the operating instructions by the safety valve manufacturer after setup of the ves- will otherwise expire. After installation of the safety valve to the valve head, the func-
sels! tion and opening pressures are reviewed again and confirmed by the employees of
Two types are used as standard: NEUENHAUSER KOMPRESSORENBAU GMBH and, if applicable, a third party (acceptance
company, customer,…) in a pressure test.
- Type "Lorch 2108", drawing Ve_20654, passage DN 8, max. The safety valves are type approved. The safety valve is suitable for the operating
blow-off performance depending on the setting pressure, open dis conditions (pressure, temperature, medium).
charge. The safety valve must be of a sufficient size for the mass or volume flow to be
With this valve the compressed air discharges directly from the valve discharged. The operator must check this!
into the surrounding atmosphere. In this it must be ensured that no

-
people are endangered by the escaping air.

Type "Leser 4383-H4", drawing Ve_23015, passage IMPORTANT!

i
DN 10, max. blow-off performance depending on the The blow-off performance of the safety valve must be checked in
setting pressure. accordance with the present compressors / conditions!
This valve has a pipe connection G ½ female. A pipe
The max. blow-off performance for compressed air is indicated on the drawings of the
can be connected to this in order to allow the blown out
safety valves in the Appendix depending on the set pressure.
air to discharge from the engine room without danger.
Further technical data on the safety valves can be taken from the manufacturer's
This is required, e.g., by the ship classification. This
documents/operating instructions (Lorch or Leser), which are included in the Appendix
prevents, e.g., that escaping compressed air does not
(chap.9) of these operating instructions.
fuel up the fire when using Halon extinguishing sys-
Additionally, further information can be downloaded from the respective website of the
tems.
manufacturers www.Leser.com / www.lorch.de.
When using a blow-off pipe on the safety valve it must
be ensured that this is sufficiently sized to allow the
arising volume flow to pass out and avoid the develop-
ment of counter pressure. The own back-pressure must
be below 15%. The blow out pipe must be laid with an incline or
i
IMPORTANT!
drained at the lowest point. The safety valve may not be operated in a downwards facing posi-
tion!
Additionally, further safety valve types/nominal widths are available upon customer Also note that special/separate requirements, such as external fire loads (ASME
request, coordinated with the operating conditions. ‘Fire Case‘ / API 520, TRB 610 – AD 2000-403,...) have not been considered in
The safety valve is set and sealed by the manufacturer. This seal protects against design of the safety valves. Therefore, they need to be indicated separately
© Neuenhauser Kompressorenbau GmbH Page 18 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

when submitting the request/order, so that the valves can be designed accord- 5.2.2 Troubleshooting, fault removal of safety valve
ingly and integrated into our offer/order. If a fault occurs in the plant that is caused by the safety valve, its cause must be
The safety valve must be tested in operation during the approval test of the in- determined and removed in any case. The plant may only be recommissioned
stallation or the complete plant. following rectification of the fault.
Settings, changes and repairs to the safety valve may only be carried out by
approved works or approved personnel. The same applies for all work and In principle the following applies to all work on the safety valve / pressure ves-
measures on all other safety installations and control and regulating installa- sel:
tions. - Depressurise all pipes and pressure chambers on the compressed air tank
and its fittings
The operating instructions of the safety valve must be observed: - Vent compressed air vessel
The safety valve (at at least 85% of the response pressure) should regularly be - Secure compressed air supply against unauthorised switching on and affix
lifted manually in order to check its function. This blows off/removes contami- repair notice.
nations at the valve seat, which are often the cause for lack of tightness and - Observe information/notes in the operating instructions of the manufacturer
leaks at the seal. of the safety valve and perform the work according to this information.
Wear suitable protective glasses, ear protectors and gloves when lifting it. We - Apply safety devices before reactivation of the plant (s. also chapter 6 on
recommend documenting these steps accordingly (vessel inspection log)! this).
Note:
The following list of faults, their possible causes and the procedure for remov-
ing them is only an overview and does not claim to be complete.
If the fault that occurred cannot be removed with the instructions in the table,
contact NEUENHAUSER KOMPRESSORENBAU GMBH!
In addition we refer you to the AD2000 regulations:
- A 2: "Safety valves" Settings, changes and repairs to the safety valve may only be carried out by
- A 403: "Installations for recognising and limiting pressure and temperature" approved works or approved personnel. The safety valve is set and sealed by
- A 6: "PLT-safety installations" the manufacturer. This seal protects against misadjustment/manipulation and
must not be removed, since any claim to guarantee will otherwise expire.

! !
Freezing, sticking or blocking of the safety valve must be avoided! In principle the following applies for all work on the plant:
Ventilate the plant first (depressurize)!

© Neuenhauser Kompressorenbau GmbH Page 19 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Fault Possible cause Remedy Fault Possible cause Remedy

Leaking/failing Foreign body in the SV Flush the system before in- Leaking/failed Caught seat/disc due to frozen Install SV in up-
safety valve stalling the SV SV liquid right/vertical/min. horizontal
(short: SV) Examine SV for foreign bodies (outlet pointing down) installa-
and remove tion position

Slightly vent SV Observe temperature range of

the SV / plant.
Dam- Insert suitable seal
aged/contaminated/defective Trace heating
Carefully clean seal/sealing
seal/sealing faces surfaces SV is opened Spring was damaged by liquid Spring hood and housing
and cannot be in the spring hood. should be emptied via drain
Replace SV if applicable closed any- bore.
Too-high ambience tempera- Replace SV according to the more. Exit piping should contain
ture → inadmissible material temperature range (coordinate drain bore as well.
expansion with Neuenhauser)
Damaged seat/(O-ring) disc Repair by the manufacturer SV opens too Difference between setting Use SV with higher setting
(e.g. due to "knocking" of the early. pressure SV and operating pressure/special valve (check
Check SV design pressure of plant is too low compatibility of the ves-
SV)
Replace sel/system).
→ Contact Neuenhauser
"stuck"/caught guide sur- Slightly vent SV according to
faces/seals operating instructions (short: Check vessel/plant pressure.
OI) Spring tension too low Increase spring tension.
Too-low area pres- Tighten SV according to manu- (see OI of the manufacturer)
sure/tightening torque facturer's information SV opens too Counter-pressure in the con- Pipe must be sized accordingly
SV separated from pressure Directly connect SV to the late. nected pipe too large (SV with and placed with a gradient
space by shut-off device pressure space corner connection)
Vessel/system contains corro- Adjust SV to operating condi- "stuck"/caught guide sur- Slightly vent the safety valve
sive media (surfaces de- tions faces/seals according to manufacturer's
stroyed by corrosion) OI.
Contaminated medium Maintenance/cleaning, subse-
→ Spindle/guide may block quent function test. Use a bel-
lows if contamination returns.

© Neuenhauser Kompressorenbau GmbH Page 20 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5.3 Drainage - for a horizontal vessel in the socket G ½ in the rim of the rear base
- for a vertical vessel with a reduction RI 1x1/2 in the socket G 1 in the centre of the
The compressed air vessel must be drained at regular intervals to prevent possible end (or in the cover)
corrosion due to arising condensation. The intervals are set according to the mode of
operation and amount of condensate. We recommend draining the vessel following Alternatively the vessel can e.g. be drained by the valve head types of form `A´ und
each filling, but at least once per week. `AE´ via a rising pipe and a drain valve on the valve head.
If automatic drainage systems and compressed air driers are used, their function is to The valve is operated via a hand wheel (open / close). By turning the hand wheel to
be checked regularly. the right / in a clockwise direction the valve and fitting is closed (see chap. 5.1.1 / 5.1.2
The passage of the drain valve and the pipes must be free. also).
The drainage valve must be laid with an incline and be sufficiently sized to draw off the
condensate. Automatic Draining:
If desired NK will supply the vessels with automatic drainage installations:
- Mechanical ball-float traps
i
IMPORTANT!
- Electronically regulated condensate discharger
The corresponding operating instructions of the respective manufacturer are part of
All drainage pipes are to be laid on an incline and with a freely ob- the Appendix (chap. 9).
servable exit!
Exit of the condensate free of danger must be assured!

Condensate which contains oil or is unclean in another way must be disposed

of in accordance with the environmental protection regulations and decrees on
hazardous substances.
If oil-water separating systems, filters or separators are used they must be suit-
able for the mode of operation and permissible.

The standard delivery of NEUENHAUSER KOMPRESSORENBAU GMBH

includes a manual drain valve according to drawing Ve_30063:
Angular valve DN 8, PN 63, G ½ male thread (entry) – G ¼ female
thread (exit), (chap. 6.13.12 / 9, item number 0051113).
The drain valve is usually supplied separately and it must be at-
tached by the operator following installation of the vessel. The drain
valve must be installed in the lowest location of the vessel.

© Neuenhauser Kompressorenbau GmbH Page 21 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

5.4 Pressure indicator 6 Handling notes

According to the AD2000 regulations and the above ship classifica- 6.1 Transport and storage
tions, a pressure vessel must be equipped with a pressure measur- Transport packaging:
ing device, e.g. a pressure gauge. A connection for this (G ½) is The vessels are delivered in a suitable transport packaging that has been agreed on
provided at the respective valve heads or the vessel itself. In it, a between NEUENHAUSER KOMPRESSORENBAU GMBH and its customers according to the
pressure gauge shut-off valve is pre-installed or enclosed loosely. order confirmation. By default, the following designs are used:
This serves to enable separation/shut-off of the pressure gauge - Wooden crate: The crate acts as protection for the vessel during truck transport
and loading. Protection against dirt, damp and humidity is not given.
from the vessel/system to replace a possibly defective pressure
- Seaworthy crate: Closed wooden box, with tarred paper on the inside, the vessels
gauge during operation. A corresponding pressure measuring de- are vacuum sealed into an aluminium laminated hood with a drying agent.
vice/pressure gauge is screwed into the pressure gauge shut-off The crate acts as protection during loading and transport, particularly during ship-
valve. ping and sea transport. According to the manufacturer, the vessels are protected
from outer influences for approx. 12 months at undamaged aluminium composite
The following pressure gauge is part of the standard delivery of NEUENHAUSER KOM- hood and professional storage.
PRESSORENBAU GMBH:
The respective designs can be delivered stackable or non-stackable. The
boxes/crates can be produced of wood that is guaranteed to be vermin-free purs. to
Standard design: item number 0061040, glycerine pressure gauge ø63, connection G
IPPC-standard ISPM 15 as well, since this is required in many countries. Furthermore
¼ below, scale 0 - 40 bar, drawing Ve_30321. the import regulations of the respective country are to be observed.
Due to danger of breaking at transport, loading and installation, the pressure gauge is
usually not delivered installed, but packed separately. Storage:
During the set-up of the vessel the pressure gauge is installed to the shut off valve by - Storage temperature -10 up to +50 °C
means of adjustable fittings provided. - Dry and dirt free,
- Protect the paintwork from damage (lightly underlay contact surfaces)
The permitted operating pressure needs to be marked with a red warning mark Vessels in seaworthy crates can also be stored outside for a certain period. However,
or similar on the pressure gauge. this must be coordinated with the manufacturer in advance!

Pressure gauges with larger diameters, other pressure levels, pressure gauges Handling of the vessels:
in safety designs, contact pressure gauges, shock reducers and pressure gauge For transporting the vessel, suitable means of transport must be used (fork lift trucks,
shut-off valves with testing connection are possible alternatively (on request). cranes, lifting apparatus, traverses / lifting beams, pallets, belts, chains, ropes, hooks,
shackles and other aids). The carrying capacity, permitted loads, weight and centres
Pressure transmitters, pressure sensors and pressure switches can be offered of gravity must be observed for this and the intended transport and load handling de-
and provided as well if required. vices must be used. Any transport/auxiliary equipment is not part of the scope of de-
livery and must be provided by the operator directly.

© Neuenhauser Kompressorenbau GmbH Page 22 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

If the containers are lifted/unloaded (without transport packaging), the existing/welded-

on supports or the vessel body itself must be used instead of or in addition to the lifting
rings (i.e.as corresponding lifting points). Crossbeams should be used for this to avoid
diagonally attacking forces. However, the vessel must not be listed by the lifting rings
while it is filled with water entirely (e.g. during hydrostatic pressure testing)! The vessel
i
IMPORTANT!
may not be raised at hand wheels or other valves and fittings. Furthermore, it must be The operator must observe the following regulations in particular:
observed that the pressure equipment, specifically the pressurised walls, must be - DGRL 2014/68/EU
treated with the utmost care, and that no chain hoists are applied for lifting. This is - Workplace Safety Ordinance (BetrSichV)
meant to prevent destruction/damage of the coating and steel structure, and thus - Guideline 2009/104/EC
maintain the corrosion protection and not undercut the calculated wall thickness! - Accident Prevention Measures (UVV)
- BG regulations - DGUV regulation 100-500 chap. 2.8
During transport the vessel must be protected against external force (impact, knocks
and vibration). In this the generally applicable transport, fastening and safety regula- - DGUV regulations 52, 54
tions must be followed, especially the regulations of the accident preventions, gov-
ernment safety organisations and insurance associations.
The weights of the vessel are indicated on/in the corresponding documents. NEUEN- 6.2 Checking on delivery
HAUSER KOMPRESSORENBAU GMBH can provide information on the weight of the asso- Scope of supply:
ciated transport packaging. The scope of supply is to be taken from the order confirmation or the delivery note.
The completeness of a delivery must be checked immediately after receipt. This ap-
plies particularly for any separately supplied components. Information about missing
or damaged parts must be passed to NEUENHAUSER KOMPRESSORENBAU GMBH imme-
diately in writing!

Transport damage:
No people may be located in the danger area! The satisfactory condition of the parts supplied must be checked as soon as the goods
are received. If transport damage is established or assumed, this should be recorded
and documented with photographs and a description of the damage. The transport
company and NEUENHAUSER KOMPRESSORENBAU GMBH must be informed of the dam-
age in writing. Include so-called hidden transport damage in your message as a pre-
cautionary measure.
Messages / complaints which are not made promptly (immediately after receipt) can
lead to loss of the insurance protection!
A damaged pressure equipment may not be commissioned under any circum-
stances!
© Neuenhauser Kompressorenbau GmbH Page 23 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.3 Set up at the operating location - Escape and emergency routes, emergency exits
- Fire, fire protection / fire extinguishing installations, sprinklers
Unless NEUENHAUSER KOMPRESSORENBAU GMBH was contracted for the set-up and - Protection from fire loads (TRB 610 - Section 3.2.3.3)
commissioning of the apparatus, only the operator or plant builder / person responsi- - Safety clearances between the plant and protection objects/safe discharge of es-
ble for the system are responsible for appropriate assembly and acceptance of the caping gases/liquids
plant. - Connections, infrastructure (electrical / compressed air network)
- Temperature value limits (internal or external set up, heat sources in the surround-
The pressure vessel is mostly resistant to environmental influence in the usual scope
ing area) → Protection against direct incident sunlight
and within the limits named in the order confirmation. Extreme environmental circum- - Accessibility of the vessel and of the rating plate for repeat tests, inspection on all
stances (temperatures, air humidity, dust build up etc.) can however lead to a reduc- sides, service, maintenance and cleaning
tion in performance, errors in functions and in the worst scenario to dangerous situa- - where required: Attachment of fences, grids, railings, warning and notice signs
tions. Please indicate such conditions to NEUENHAUSER KOMPRESSORENBAU GMBH for (protection from intervention/access by unauthorised parties)
review. If appropriate, particular protective measures may be required. - Protection against contamination
- Protection from outer (mechanical) effects/loads
- Optical and acoustic warning installations, signals, alarms
The floor preparations on site must be performed independently and professionally by
the customer or a company charged by him. The set-up must be carried out by quali-
The previously listed items must be observed and implemented by the operator under
fied specialised personnel. The relevant European and international guidelines must
all circumstances. Also the foundations, fixtures and attachments are created by the
be observed in this.
operator himself. On agreement the NEUENHAUSER KOMPRESSORENBAU GMBHcan
The vessel must be set up and secured in such a way that there is no danger to the
supply suitable fasteners for the vessel. These can be e.g. welded on feet, saddles or
surrounding area, workers and third parties.
brackets. However, it is strictly forbidden to subsequently weld any support
Suitable holders, bases, dowels and screws must be used depending on the vessel
equipment, such as the above, to the vessel body or pressurised parts! In gen-
weight and situation on site (construction soil properties, earthquake zone, etc.).
eral no unauthorised conversions or changes to the pressure vessel or the
Therefore it can be necessary that particular (external) loads are to be accommodated
valves and fittings may be undertaken.
or reduced by use of reinforcements, supports, compensators or mountings.
Depending on the set up it may be necessary as well to fit vibration dampers. The vessel is usually to be set up in such a way that the draining installation is
at the lowest point of the vessel. Standard horizontal vessels are to be set up with
The following points are to be taken into account in particular: an angle of inclination of 1 to 5° (valve head at the upper end).
- Attachment, securing against tipping over, falling and slipping
- Foundation, laying foundations while taking into account the actual weight, operat- Open connections are closed with flange covers, plastic caps and plugs for
ing weight and full weight in water pressure test temporary protection and closings during transport or storage. These are not
- Operability of the vessel and the equipment / valves and fittings, ergonomic princi-
ples, clarity, illumination. suitable for pressure operation and they must be exchanged prior to commis-
- Choice of location: inner / outer, collision protection, crane tracks sioning.
- Traffic routes

© Neuenhauser Kompressorenbau GmbH Page 24 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Observe that and check before COMM that no dirt/foreign bodies are in the vessel and - Pressure surges, water surges, pressure/hydraulic fluctuations should be avoided.
the valves, since this may influence function. - If necessary, thermally caused expansions of pipes should be observed (installa-
tion of corresponding flexible elements / lines and compensators).
After setting up the vessel (prior to commissioning at the latest), a thorough induction
of the operating and maintenance personnel must take place by the plant operator. The connection flanges and threads must match those at the vessel.
The installation position of the vessel and the valves and fittings must be ob-
6.4 Assembly instructions served. The prescribed flow direction must be observed if applicable. The op-
erator is responsible for this.
It must be ensured that the complete plant (e.g. compressed air network, pipes and
compressor or pressure generator) meets the relevant regulations and technical rules.
The torque of bolts, nuts and screws is to be adhered to. The manufacturer will pro-
This is solely the plant operator's responsibility.
vide the corresponding tightening torques on request. Gaskets between flanges must
Additional loads and vibration loads on the vessel and its supports are to be prevented
be centred. Piping fittings with progressive rings and similar hydraulic / pneumatic
by the operator by appropriate measures.
fittings have to be installed according to the maker’s instructions. The assembly tech-
The pipes are to be laid in such a way that damaging thrusting, shearing, bending and
nician must be qualified and trained adequately.
torsional forces are avoided. Ensure tension-free installation, e.g. by flexible hoses or
compensators. In addition to this, the corresponding clamp holders and supports for
6.5 Operation
the connected pipes should be used.
The pressure vessel was built according to the current state of the art and is opera-
tionally safe in compliance with the operating instructions and analysis of the dangers

Note
i and risks.

Dangers to life and limb to the operating personnel or third parties can result from the
The entire piping system must be cleaned/flushed, free of contami- pressure vessel or interference with the apparatus.
nation and foreign particles, tested for tightness and subjected to a It must be ensured that the vessel is operated in line with regulations, appropriately
hydraulic/pneumatic inspection before commissioning of the vessel and safely.
and the fittings! The use of the pressure vessel in line with regulations involves the storage of
compressed air (or other media such as e.g. water) with the valid technical pa-
The valves and fittings and other components must be selected according to the mode rameter limits given in sections 4.3 ‘Setup of the pressure equipment, technical
of operation. All materials, valves and fittings, pipes, flanges, bolts, gaskets etc. must data‘ and 4.4 ‘Design Characteristics‘.
be suitable for the medium, pressure and temperature. Additionally, the following must
be observed for the fittings: For this generally compressed ambient air is to be used as a storage medium. The oil
- Reaction forces from sudden opening of ball valves and valves should be avoided. residues which may be contained in the compressed air from the compressor must
- Needle valves/valves with hand wheel shut-offs should be used with preference. correspond to the oil types given in the lubrication oil recommendation.
© Neuenhauser Kompressorenbau GmbH Page 25 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

The compressed air must be free of solid shares to ensure proper function of the Before switching on / starting up it must be ensured that the plant is in an operational
valves. An appropriate filter / separator is to be used on the air compressor. state with correct safety devices. No one who is not specifically authorised to do so
Additionally, the media water, water with air padding and nitrogen (only in coordination may be present in the danger area of the vessel during operation, may work on its
and under observation of temperature, etc.) may be used as well. peripheral components or undertake any other measures or interfere with the opera-
tion.
Any use beyond this purpose is not in line with regulations. NEUENHAUSER KOMPRES- Freezing of the vessel or the valves and fittings must always be prevented. Therefore
SORENBAU GMBH will not be liable for any damage which results from such use. The in principle precautions against freezing must be taken for all plants at risk from frost.
risk is borne solely by the operator. The same applies for damage which results from For temperatures of ≤ +0 °C (only when depressurised), no water must be in the
inappropriate handling and / or treatment of the pressure vessel or its peripheral instal- vessel, the lines or fittings. Because freezing water can destroy components and
lations. also block pipes and valves.
Before every COMM, the pressure vessel must be inspected for operational safety, Freezing of the safety valve must be prevented in particular (see chapter 5.2).
outwardly visible damage and the safety devices for unlimited readiness for operation. Therefore, the arising condensation in the vessel must be discharged at regular inter-
Furthermore, all required protection devices must be installed. vals.

When removing old materials and hazardous materials, the environmental protection
Operation may only be carried out by suitably qualified and inducted personnel.
regulations and regulations on hazardous substances must be strictly adhered to.
The operator is responsible for this.
Every person who is given a task which is indicated in the operating instructions at the
The function and operation of the valves is explained in chapter 5.
location of the vessel /assembly / plant or in the workshop must have read and under-
stood the full set of instructions. Additionally, the operator must draw up (usage) in-
6.6 Testing of the set up
structions for proper operation of the pressure vessel and its attachments (commis-
sioning/decommissioning, maintenance/servicing, conduct at faults, etc.). Both these The commissioning is to be reported to the responsible factory inspectorate or the
operating instructions and the (usage) instructions must be kept in direct proximity of responsible inspection body.
the plant and must be accessible to the operating staff to permit looking things up The operator must arrange an inspection of the operational vessel, the set up and the
later. complete equipment with all valves and fittings, with safety valve, pressure generator,
pipework etc. with the authorised inspection office. A vessel inspection log book must
Safe working techniques are to be used for all works. The industrial safety and acci- be kept in which the tests are recorded and archived. A risk assessment must be
dent prevention measures (UVV) are to be observed with possible local /national addi- drawn up additionally. This is part of the plant operator's responsibility!
tions. Each way of working or operating mode which affects the safety of the person or
the pressure equipment is to be refrained from. If there is a change in set up or mode of operation, new start up after shut down,
Cleanliness and clear arrangement at the set up location must be ensured. Access to conversions or change of the vessel location, a new inspection is required.
the vessel and its valves and fittings must always be guaranteed. The operator must report this to the relevant surveillance authority immediately.

© Neuenhauser Kompressorenbau GmbH Page 26 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.7 Maintenance, Upkeep and Inspection

The pressure vessel (and valves and fittings) is/are low maintenance and insensitive
due to its construction.

The pressure vessel (and valves and fittings) may only be used, maintained and kept
!
up by skilled people who are well versed in it and in the operating instructions and Before any installation, repair and maintenance work:
have been informed about all dangers. First bleed air from plant (depressurize)!
Repair work must only be performed by specifically trained persons and may need to
be reported to the relevant audit office beforehand.

The vessel must be protected from wetness, extreme heat/cold, dirt, damage and
other harmful weather influences (wind, snow,…).
The operating company schedules the maintenance intervals according to operating
!
conditions and operational experience (also see chapter 6.10).
The vessel is to be cleaned regularly (depending on mode of operating) and examined Staying in the danger area is prohibited!
for damage, cracks, dents, distortion, damage to the corrosion protection, leaks and
rust.
Damage which is noticed must be rectified without delay. 6.8 Inspection
In the case of doubt discuss with the manufacturer! E.g. the block flanges serve inner coating/inspection of the vessel. They are
closed/sealed by the valve head or lid in connection with a flange seal (item no.
No aggressive, easily flammable or health endangering solvents or cleaning agents or 0058979) and the associated tightening torque of the nuts M20x2 (according to manu-
materials which contain tri-, per- or tetrachloroethylene may be used for cleaning pur- facturer's information - information on request) and must be disassembled for coat-
poses. ing/inspection.
The vessel can be cleaned internally through the block flange and examined for corro-
Maintenance work may only be carried out when the plant is switched off. The vessel sion, cracks and other damage. If auxiliary equipment is needed for this, such as an
is to be separated from the compressed air network and vented entirely. The plant endoscope or similar, this must be provided by the operator.
must be secured against possible restarting.
The plant must be secured against the entrance or interference of unauthorised per- For other vessel sizes and special versions, other arrangements of inspection open-
sons. ings may be required. In this case we refer you to the specific job-oriented drawing.
The position, number, size and / or type of inspection openings (e.g. head hole, hand
Worn or damaged components must be replaced without delay. hole or manhole covers) are specified according to the order.
Only original spare parts may be used for this purpose.
© Neuenhauser Kompressorenbau GmbH Page 27 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.9 Opening under pressure nothing unforeseen occurs.

The periods for the recurring inspections are specified by the expert of the notified
Opening the vessel under pressure is extremely dangerous and must be re- body (e.g. TÜV), by the ship classification (e.g. DNV-GL), its regulations and/or na-
frained from at all times! The vessel must be ventilated before any work on it tional or local provisions. The respective shortest periods from the applicable regula-
can take place! tions/provisions apply for this.
As a rule an internal examination is carried out once every five years and a pressure
The vessel can be depressurized via the various valves on the valve head or the drain test once every ten years. Additionally, an outer inspection should take place every 2
valve. For this pipes, valves and fittings or other appliances may have to be removed. years, usually on the compressed air vessel in operation.
A danger free exit of compressed air must be ensured. No people may be located in The times may be set differently if there are particularly aggressive media, strong cor-
the danger area. rosion, certain load change numbers (“cycles to failure”) are reached or there are
In every case the pressure must be checked at least at two pressure gauges prior to other particular operating conditions and experiences. Internal inspections must be
opening. It must be ensured that the pressure gauge shut-off valves are opened supplemented or replaced by pressure tests or other suitable inspections as well if the
so that the pressure gauges display the actually present vessel pressure. inner inspections cannot be performed at the required scope. Pressure tests must be
replaced by non-destructive tests when pressure tests are not possible or not suitable
A safety device preventing opening under pressure is usually not provided. Opening of due to the build or operating mode of the vessel.
this type of vessel is not required for the general normal mode of operation. The ves- If applicable, extension of the above period is possible as well where safety is ensured
sel only needs to be opened for maintenance and testing when the plant would be out otherwise and this has been specified by the independent third party.
of operation in any case. The recurring tests are registered with the authorised inspection office (e.g. TÜV)/the
relevant ship classification and carried out by them.

! The operator is responsible for adherence to the test periods and arrangement and
carrying out of the tests. These test data must be recorded in the vessel test log and
archived. All other service work must be entered in this vessel test log as well.
The vessel must not be opened under pressure!
Additionally, the operator is responsible that necessary equipment / auxiliary tools and
special equipment such as endoscopes are provided for the recurring inspections.
6.10 Recurring inspections The vessel also must only be used as intended, after performance of the required
After the vessel (+fittings) has been subjected to a first successful inspection consist- inspections in time and successfully, i.e. when the corresponding requirements have
ing of preliminary test, construction test and pressure test before deliv- been met, and this has been certified by an expert.
ery/commissioning in the manufacturer's factory (if applicable in presence of the inde-
pendent third party), recurring inspections must be performed at specific intervals. Additionally, we as the manufacturer recommend replacing the vessel + fittings after
Thus, the operational safety of the vessel (+fittings) is ensured from until the first re- an operating time of 25 years at most to bypass invisible risks (such as ageing, mate-
curring inspection provided that the specified usage thresholds are complied with and rial fatigue, tension crack corrosions, etc.).

© Neuenhauser Kompressorenbau GmbH Page 28 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Outer coating:
The outer coating of the vessel is made up of a layer of corrosion protection primer

IMPORTANT!
i and a layer of synthetic resin paint (standard: RAL 7031). They add up to a total dry
film layer of at least 80 μm.

The prescribed inspection periods for the recurring inspections In spite of the full-surface coat of paint inside and outside of the vessel, and the
must be observed and apply to the valve head/fittings as well! welded-on support, the vessel construction/design provides points of attack for corro-
sion. They are mostly found at/in threads, sealing areas (edges) and the screw head
6.11 Corrosion, Wear or nut support surfaces. Such positions require regular inspection by the plant opera-
tor and must be improved accordingly!
Corrosion, wear and wall-thickness tolerances have generally been considered in the
calculations with a surcharge according to the regulations and/or project (in coordina- Other coating systems must be coordinated with NEUENHAUSER KOMPRESSORENBAU
tion with the customer). GMBH and specified precisely in the request/order.
If the wall thicknesses are gone below by this value, further operation of the vessel is
not permitted. This must be reviewed at least at the intervals named in the previous
chapter 6.10. However, we recommend more regular review and, if applicable, coordi-
nation with NEUENHAUSER KOMPRESSORENBAU GMBH.

Below, you will find the execution of the vessel coating according to the NEUEN-
i
IMPORTANT!
HAUSER-standard. The surface is prepared by sand blasting and a resulting appropri-
The vessel must be checked regularly for corrosion and wear (see chapter
6.10)!
ate degree of purity/roughness.

Internal coating:

i
The vessels are coated with a two-layered corrosion protection coating inside by de-
fault. These two layers result in a total dry film thickness of at least 120 μm. The coat-
ing is resistant to the oils shown in the oil specification at the operating temperature
given for the vessel. Permanent resistance to vegetable oils (bio oils/-diesel) and oil IMPORTANT!
mixtures with detergents and/or alkalis (cutting and boring oil) is not guaranteed. The compressed air must be free of solid components! An appropriate filter /
separator is to be used on the air compressor!
For more precise information, see the enclosed lubrication oil recommendations, or
All pressure transmitting pipes must be free of dirt and other particles!
inquire about them from NEUENHAUSER KOMPRESSORENBAU GMBH. Different operating
conditions must be agreed with the manufacturer.

© Neuenhauser Kompressorenbau GmbH Page 29 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.12 Troubleshooting
The cause of a problem must always be identified and rectified. The plant may
only be recommissioned following rectification of the fault. !
In principle the following applies to all work on the compressed air receiver:
- Secure compressed air supply against unauthorised switching on and affix In principle the following applies for all work on the plant:
repair notice. Ventilate the plant first (depressurize)!
- Depressurise all pipes and pressure chambers on the compressed air tank
and its fittings
- Vent compressed air vessel
- apply safety devices before commissioning

Leaks:
!
If there are cracks, holes, shrinkage cavities, expansion and other damage to If there are cracks, holes, shrinkage cavities, expansion and other
plates, housings and welds, the vessel / valve head must be shut down immedi- damage to plates, housings and welds, the vessel must be shut
ately! The manufacturer and the responsible inspection body must be informed! down immediately!
Any unauthorised welding repairs are not permitted!

Note:
Residues in the pipes and valves and fittings (dirt, welding spatter, filings etc.)
will inevitably lead to leaks, damage or blockage of the pipes and valves.
Cleanliness must be ensured during assembly, start up and during operation.
i
IMPORTANT!
Any unauthorised welding repairs are not permitted!
A well looked after machine/plant always gives an idea as to the care of the ma-
chinist, helps avoid operational faults and increases the working life.

Find a table below that lists some faults with their causes and a possible quick
remedy. This table is only an overview and does not claim to be complete.

© Neuenhauser Kompressorenbau GmbH Page 30 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Fault Possible cause Remedy Fault Possible cause Remedy

no flow valve and fitting closed open valve and fitting Lack of seal on packing sleeve too loose tighten packing sleeve (screw
through flange covers, caps and plugs remove flange covers valve spindle cap)
were not removed - Valve inset DN 38: SW 55
- Valve inset DN 50: SW 55
- Valve inset DN 18: SW 41
little flow valve and fitting not open suffi- open valve and fitting - Valve inset DN 12: SW 32
through ciently The packing sleeve must not
dirty filter, dirt trap clean strainer or replace be too tight as the valve will
otherwise be hard or impos-
blockage in pipe system check and clean pipe system sible to operate.
If required, re-pack the packing
difficult opera- dry spindle lubricate spindle sleeve (renew packing) or
tion / valve and replace the whole valve insert
packing sleeve too tight loosen screw cap slightly but
fitting cannot (see chapter 6.13).
the seal must still be guaran-
be opened teed further.

Lack of seal on incorrect, unsuitable connect- Use suitable sealing materials

incorrect direction of rotation observe direction of rotation
gaskets, ing elements,
(anti-clockwise equals: open)
flanges and Assembly fault Use suitable screws
Valve not tight not fixed tight Tighten the hand wheel with- pipe connec-
at valve seat out any aids tions
Matching of the connecting
Valve seat damaged by foreign replace the whole valve seat flange
bodies (refer to chapter 6.13)
Tighten screw connections
Contamination on the seat Clean valve and fitting, install evenly (crosswise/diagonally),
/cone, contaminated medium dirt trap in before valve and observe correct torque.
(solid particles) fitting
Install parts without tension
Problems see chapter 5.2.2 see chapter 5.2.2
with/at the Centre parts and gaskets and
safety valve don't tilt

© Neuenhauser Kompressorenbau GmbH Page 31 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

Fault Possible cause Remedy

Lack of seal on Seals defective, damaged or Replace gaskets
gaskets, contaminated surfaces
Check condition of the sur-
flanges and
faces (sealing surfaces) and
pipe connec-
clean if appropriate
tions
Replace damaged parts
Drainage blocked drainage valve, clean system
doesn't work blocked drainage pipe

Valve head form “A”: fit drainage pipe

Drainage pipe not fitted / not Only fit valve head form “A”,
present “AE” for a standing (vertical)
incorrect installation position of vessel
the vessel
automatic drainage installa- The operating instructions of
tions: the manufacturer are to be
unsuitable appliance observed
incorrect method of fitting,
incorrect installation position,
way of connecting, piping,
voltage supply

© Neuenhauser Kompressorenbau GmbH Page 32 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13 Repair work on the valve head

The vessel is supplied by NEUENHAUSER KOMPRESSORENBAU GMBH with a valve head,
the function and sealing of which has been tested. The assembly, the materials, func-
tion test, leakage and pressure test are documented with an acceptance certificate 3.1
purs. to EN 10204 for each valve head.
The valve heads of the nominal widths DN 38 and DN 50 are attached with four studs
!
The plant must be vented (depressurised) before assembly, repair
and nuts M20x2 (spanner size SW 30) at the vessel flange DN 100. A flat gasket (item and maintenance work!
no. 0058979) is used as sealing. The valve head DN 80 is installed with six studs and
nuts M27x2 (spanner size SW 41) at the vessel flange DN 200. The vessel is sealed
with a flat seal (item no. 0055319) here. The required tightening torque of the nuts
must be considered according to the manufacturer's information.

For all repair work on the valve head it is recommended to use a bit of grease or
oil so that blank surfaces are protected against rust, moving parts and threads
remain movable and rusting tight and seizing of the parts is avoided.
New gaskets should be used for each fitting / removal of parts of the valve head.
For gasket sets, see chapter 6.14.

You will find all the drawings named in this chapter in the appendix of the operating
instructions.
Spare parts:
Lists of spare parts, descriptions and designations of the spare parts are added to
these operating instructions in the form of drawings and parts lists or can be provided
on demand. We keep the spare parts named available in the warehouse and deliver
them worldwide immediately.

© Neuenhauser Kompressorenbau GmbH Page 33 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.1 Replacing valve inset DN 38

Valve inset DN 38
Drawing Ve_30123
Item no.: 0059493
The complete valve inset can be replaced. The valve insert DN 38 is also part of the Locking plate
valve head DN 80 (see chapter 5.1.3).
 Loosen the locking plate
 Unscrew the spindle guide (size SW 55) in an anti-clockwise direction.
Copper gasket Snap-ring 60x2
 Check the valve seat, bore, thread and passage and clean if necessary. 65x74x2.5
 Replace the copper gasket ring Cu 65x74x2.5.
 Screw in the new valve inset with a little grease (Vaseline), tighten it; for this the
spindle must be in an open position (turned out in an anti-clockwise direction).
 Secure locking plate. Valve seat DN 38
 Check for leak-tightness.

6.13.2 Replacing valve seat DN 38

Drawing Ve_30103
Item no.: 0057345
The valve seat can be replaced. The valve seat DN 38 is also part of the valve head
DN 80 (see chapter 5.1.3).
 Remove valve inset DN 38 (see chapter 6.13.1) in order to reach the valve seat.
 Remove the securing ring 60x2 with circlip pliers (for inner rings).
 Pull out the valve seat (sealing ring with thrust ring) or press it out; in order to make
this easier the valve seat has two small holes.
 Cleaning the valve seat receptacle.
 Insert the new valve seat with a little grease (Vaseline).
 When fitting ensure that the edges of the plastic ring are not damaged. Tools:
 Fit a new snap-ring. - Open ended spanner, ring spanner SW55
 Install the valve seat (see chapter 6.13.1). - Open ended spanner SW19
- Slot screwdriver (approx medium size 7.0x125)
- Hammer (medium size approx 1000 g)
- Pipe, rod, plastic block, squared timber or similar
- Circlip pliers DIN ISO 5256 C straight form 40x100 (e.g. NK item no. 0095410)
© Neuenhauser Kompressorenbau GmbH Page 34 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.3 Replacing valve inset DN 50 .

Valve inset DN 50

Drawing Ve_30146
Item no. 0059444
The complete valve inset can be replaced: Locking plate
 Loosen the locking plate
 Unscrew the spindle guide (size SW 55) in an anti-clockwise direction.
 Check the valve seat, bore, thread and passage and clean if necessary.
Snap-ring 60x2
 Replace the copper gasket ring Cu 78x88x2.5. Copper gasket
 Screw in the new valve inset with a little grease (Vaseline), tighten it; for this the 78x88x2.5
spindle must be in an open position (turned out in an anti-clockwise direction).
 Secure locking plate.
 Check for leak-tightness.

6.13.4 Replacing valve seat DN 50 Valve seat DN 50

Drawing Ve_30160
Item no. 0059354
The valve seat can be replaced.
 Remove valve inset DN 50 (see chapter 6.13.3) in order to reach the valve seat.
 Remove the securing ring 75x2.5 with circlip pliers (for inner rings).
 Pull out the valve seat (sealing ring with thrust ring) or press it out; in order to make
this easier the valve seat has two small holes.
 Cleaning the valve seat receptacle.
 Insert the new valve seat with a little grease (Vaseline).
 When fitting ensure that the edges of the plastic ring are not damaged.
 Fit a new snap-ring.
 Install the valve seat (see chapter 6.13.3)
Tools:
- see chapter 6.13.1 / 6.13.2

© Neuenhauser Kompressorenbau GmbH Page 35 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.5 Replacing valve inset DN 18 .

Copper gasket 42x49x2
Drawing Ve_30133 / Ve_30157
Item no. 0059474
The complete valve inset can be replaced. The valve insert DN 18 is used both for the Valve inset DN 18
valve head DN 38 and DN 50 (see chapter 5.1.1 / 5.1.2).
 Loosen the locking plate
 Unscrew the spindle guide (size SW 41) in an anti-clockwise direction.
 Check the valve seat, bore, thread and passage and clean if necessary.
 Replace the copper gasket ring Cu 42x49x2.
 Screw in the new valve inset with a little grease (Vaseline), tighten it; for this the
spindle must be in an open position (turned out in an anti-clockwise direction).
 Secure locking plate.
 Check for leak-tightness.

6.13.6 Replacing valve seat DN 18

Locking plate
Drawing Ve_30137
Item no. 0057610 Valve seat DN
The complete valve seat can be replaced. The valve seat DN 18 is used as a counter- 18
part for the valve insert in the valve heads DN 38 and DN 50 as well (see chapter
5.1.1 / 5.1.2).
 Remove valve inset DN 18 (see chapter 6.13.5) in order to reach the valve seat.
Tools:
 Screw the valve seat out in an anti-clockwise direction - internal hexagon wrench - Open ended spanner, ring spanner SW41
size 17 mm. - Open ended spanner SW17
 Cleaning the valve seat receptacle. - Slot screwdriver (approx. medium size 7.0x125)
 Screw in the new valve seat with a little grease (Vaseline) so that the tightened - Hollow hexagon wrench (Allen key) SW 17
sealing edge fits tightly.
 Install the valve seat (see chapter 6.13.5)

© Neuenhauser Kompressorenbau GmbH Page 36 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.7 Replacing valve inset DN 12 .

Drawing Ve_30152
Item no. 0059562
The complete valve inset can be replaced: Copper gasket 42x49x2

 Loosen the locking plate

 Unscrew the spindle guide (size SW 32) in an anti-clockwise direction.
 Check the valve seat, bore, thread and passage and clean if necessary.
 Replace the copper gasket ring Cu 30x36x2.
 Screw in the new valve inset with a little grease (Vaseline), tighten it; for this the
spindle must be in an open position (turned out in an anti-clockwise direction). Valve inset DN 18

 Secure locking plate.

 Check for leak-tightness.

6.13.8 Replacing valve seat DN 12 Valve seat DN

18
Drawing Ve_30156
Item no. 0059590 Locking plate
The complete valve seat can be replaced.
 Remove valve seat DN 12 (see 6.13.7) in order to reach the valve seat.
 Screw the valve seat out in an anti-clockwise direction - internal hexagon wrench
size 11 mm.
 Cleaning the valve seat receptacle. Tools:
 Screw in the new valve seat with a little grease (Vaseline) so that the tightened - Open ended spanner, ring spanner SW32
sealing edge fits tightly. - Open ended spanner SW17
 Install the valve seat (see chapter 6.13.7) - Slot screwdriver (approx medium size 7.0x125)
- Hollow hexagon wrench (Allen key) SW 11

© Neuenhauser Kompressorenbau GmbH Page 37 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.9 Replacing valve inset DN 80 .

Valve inset DN 80
Drawing Ve_30116
Item no. 0059446
The complete valve inset can be replaced:
 Unscrew the spindle guide (size SW 115) in an anti-clockwise direction.
 Check the valve seat, bore, thread and passage and clean if necessary.
Copper gasket
 Replace the copper gasket ring Cu 126x139x2. 126x139x2
 Screw in the new valve inset with a little grease (Vaseline), tighten it; for this the
spindle must be in an open position (turned out in an anti-clockwise direction).
 Check for leak-tightness. Snap-ring 120x4

6.13.10 Replacing valve seat DN 80

Drawing Ve_30107
Item no. 0059447
The complete valve seat can be replaced.
 Remove valve inset DN 80 (see chapter 6.13.9) in order to reach the valve seat.
 Remove the securing ring 120x4 with circlip pliers (for inner rings).
Valve seat DN 80
 Pull or push out the valve seat (sealing ring with supporting ring).
 Cleaning the valve seat receptacle.
 Insert the new valve seat with a little grease (Vaseline).
 When fitting ensure that the edges of the plastic ring are not damaged.
 Fit a new snap-ring.
 Install the valve seat (see chapter 6.13.9)

Tools:
- Open ended spanner, ring spanner SW115
- Hammer (medium size approx. 1000 g)
- Pipe, rod, plastic block, squared timber or similar
- Circlip pliers DIN ISO 5256 C straight form 40x100 (e.g. NK item no. 0095410)

© Neuenhauser Kompressorenbau GmbH Page 38 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.11 Replacing the safety valve 6.13.12 Replacing of angular valve / pressure gauge shut-off valve

The safety valve is installed in a G ½ connection in all three valve head sizes. As men- The corner valve listed in chapter 5.3 (drawing Ve_30063, item no. 0051113) is used
tioned in chapter 5.2.1, two types of safety valves are used by default. The following as a pressure gauge shut-off valve, auxiliary air valve and drainage valve. The valve is
open-ended spanners/ring spanners are needed for installation: (dis)assembled with an open ended spanner / ring spanner of size SW 22. The direc-
 Type “Lorch 2108”: Size SW 27 tion of the valve is performed as in the safety valve by the thickness of the copper
 Type “Leser 4383-H4”: Size SW 36 gasket ring Cu 21x26x1.5 (...x2, ... x2.5) used.
The direction of the “Leser” safety valve is adjusted by the thickness of the copper
NK angular valve/
gasket ring Cu 21x26x1.5 (...x2, ... x2.5) used. pressure gauge shut off valve
Copper gasket 21x26
The correct setting pressure must be observed. The data of the safety valve must be
checked precisely. Adjustments and other changes to the safety valve may only be
undertaken by people authorised to do so (see chapter 5.2). SW 22

The pressure gauge shut-off valve installed at the valve head DN 80 (with test connec-
tion item no. 0054552) is attached in connection with a shock reducer. Both the pres-
sure gauge shut-off valve and the shock reducer have a hexagon with wrench size
SW 36 SW 27. Copper gasket 21x26

Pressure gauge shut off

valve with testing connection
with test connection
SW 27

Shock reducer
Copper gasket 21x26 Safety Valve
(presentation of both SW 27
standard types)

© Neuenhauser Kompressorenbau GmbH Page 39 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.13.13 Replacing the air relief valve

The venting valve (drawing Ve_30141, item no. 0059655) is produced and installed
according to the Neuenhauser drawings. The housing is applied with a hexagon of
size SW 27. This valve is only used for the valve head DN 38 and vents the start-up
air line towards the motor.

Copper gasket 21x26

SW 27

Air relief valve

6.13.14 Replacing angular valve DN 16 up to DN 20

The corner valve DN 16 (drawing Ve_30244, item no. 0057939) to DN 20 (drawing
Ve_30383, item no. 1088500) is a valve that is produced and installed according to
the specifications and drawings of NEUENHAUSER KOMPRESSORENBAU GMBH. This
corner valve is mostly used as auxiliary air or typhoon valve. An open-ended spanner
of size SW 60 is needed for installation.

Corner valve DN 16 to DN 20
Copper gasket 33x39

SW 60

© Neuenhauser Kompressorenbau GmbH Page 40 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

6.14 Gasket sets 2x copper gasket 33 x 39 x 2 (0056297)

2x copper gasket 33 x 39 x 2.5 (0581176)
Gasket kit for valve head DN 38
Item no. 0061232 consisting of 6.15 List of tools
1x flat gasket 105 x 120 x 2 (0058979)
1x copper gasket 65 x 74 x 2.5 (0054547) Open ended spanner / ring spanner SW19 Plug G 1/2
1x copper gasket 50 x 57 x 2 (0059128) Open ended spanner / ring spanner SW27 Plug G 1
1x copper gasket 42 x 49 x 2 (0059124) Open ended spanner / ring spanner SW30 Nuts M20x2 (valve head oval flange)
2x copper gasket 21 x 26 x 1.5 (0059125) Open ended spanner / ring spanner SW32 Screw cap valve inset DN 12
2x copper gasket 21 x 26 x 2 (0056290) Open ended spanner / ring spanner SW41 Screw cap valve inset DN 18
2x copper gasket 21 x 26 x 2.5 (0059221) Open ended spanner / ring spanner SW55 Screw cap valve inset DN 38 / 50
Open ended spanner SW10 Hand wheel ø60
Gasket kit for valve head DN 50 Open ended spanner SW14 Pressure gauge
Open ended spanner SW17 Hand wheel ø125 / ø100, pressure
Item no. 0061293 consisting of
gauge bolts
1x flat gasket 105 x 120 x 2 (0058979) Open ended spanner SW19 Hand wheel ø160, pressure gauge
1x copper gasket 78 x 88 x 2.5 (0059130) bolts, bolts for drainage pipe
1x copper gasket 65 x 74 x 2.5 (0054547) Open ended spanner SW22 Angular valve
1x copper gasket 42 x 49 x 2 (0059124) Open ended spanner SW27 Safety valve type “Lorch 2108”, air
1x copper gasket 30 x 36 x 2 (0059126) relief valve
2x copper gasket 21 x 26 x 1.5 (0059125) Open ended spanner SW36 Safety valve type “Leser 4383”
2x copper gasket 21 x 26 x 2 (0056290) Hollow hexagon wrench SW11 Valve seat DN 12
2x copper gasket 21 x 26 x 2.5 (0059221) Hollow hexagon wrench SW17 Valve seat DN 18
Slot head screwdriver Locking plate
Gasket kit for valve head DN 80 (approx. medium size 7.0x125)
Item no. 00635986 consisting of Hammer (medium size approx 1000 g) to install the valve seat DN38/DN50
1x flat gasket 200 x 230 x 2 (0055319) (using, e.g., a tube, plastic block or
1x flat gasket 138 x 82 x 2 (0059667) similar)
1x copper gasket 139 x 126 x 2 (0054544) Circlip pliers Inner rings 60x2 / inner rings 75x2.5
1x copper gasket 65 x 74 x 2.5 (0054547) (e.g. DIN ISO 5256-C straight form 40x100)
2x sealing edge ring DKI R 1/2 (0054136) Pipe wrench Splash pipe
2x copper gasket 21 x 26 x 1.5 (0059125)
2x copper gasket 21 x 26 x 2 (0056290)
2x copper gasket 21 x 26 x 2.5 (0059221)
2x copper gasket 33 x 39 x 1.5 (0580719)
© Neuenhauser Kompressorenbau GmbH Page 41 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

7 Guarantee The valid status can be called up on the web-site www.nk-air.de /

www.neuenhauser.de. Particular conditions can be agreed in relation to the specific
The vessel (including accessories) meets the current state of technology and the
order.
safety regulations which apply at the time of delivery. We guarantee the vessel sup-
plied is free of faults.

The duration of the guarantee is 12 months following commissioning, limited to

a maximum of 24 months from the time of delivery. It only remains valid under
strict observation of and compliance with the applicable notes in these operat-
ing instructions.
Deviating agreements must be contractually specified with NEUENHAUSER KOM-
PRESSORENBAU GMBH, since the above warranty period will apply otherwise!

No guarantee is given for damage which occurs due to the following reasons:
- inadmissible mode of operation, non-observance of the technical operating condi-
tions (such as pressure, temperature and operating medium in particular)
- improper treatment and storage
- non-observance of the operating instructions
- non-observance of the relevant technical complex of rules
- insufficiently trained or inducted operating personnel
- incorrect or negligent handling of the pressure vessel or the pressure plant
- Natural wear/wear parts are excluded from the warranty.
- aggressive media in the vessel
- use of oils which are not shown in the attached oil specification

In addition the guarantee claim lapses for

- changes and conversions on the pressure vessel and its components, in particular
on the safety installations which are inappropriate or which have not been ap-
proved by the NEUENHAUSER KOMPRESSORENBAU GMBH beforehand.
- non-observance of the prescribed inspection on commissioning and the time peri-
ods for the recurring tests.

In addition we refer you to our general terms and conditions.

© Neuenhauser Kompressorenbau GmbH Page 42 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

8 Spare parts, Customer service the appendix serve to identify the item numbers of the spare parts needed.

All spare parts are always kept in stock in our comprehensive spare parts storage and
Safety valves
will be combined into spare parts packages on request. They can be dispatched as
Observe that the spare parts drawings Ve_30400, Ve_30401 and Ve_30402
quickly as possible worldwide. Our specialist installers will be available to you for re-
named above each contain both safety valve types, but that only one of them is
pairs in addition to this.
installed!
The safety valves are set and sealed by the manufacturer.
Necessary spare and wearing parts can be identified, indicated and ordered via the
For orders of safety valves, the type (standard types: Leser “4383“ or “Lorch 2108“)
drawings listed in the appendix. Drawings of spare parts are included in the appendix
and the setting pressure must be indicated.
of these operating instructions.
Information on the setting pressure of the respective blow-off performance and the
associated item number can be taken from drawings Ve_23015 and Ve_20654. The
The following information should be given in spare part orders:
setting pressures listed there
- Pressure vessel - / valve head - type (size, form)
- Serial number of the vessel and / or valve head
- Delivery address
- desired form of dispatch, delivery date

Spare parts valve head

Chapter 6.13 contains notes on the assembly process for exchange of the most impor-
tant spare parts of the valve head designs and their descriptions. The appendix con-
tains both spare parts drawings of the respective valve head nominal widths and the
assemblies used there.

Valve head DN 38 / 50
The possible designs of the valve head nominal widths DN 38 and DN 50 are listed in
the information and the tables of chapters 5.1.1 and 5.1.2 respectively. These tables
contain the valves installed with the respective design. The spare parts drawings
Ve_30401 and Ve_30402 contain all of these valves, all other parts and the item num-
bers required for re-orders.

Valve head DN 80
This is different for valve head DN 80, however. This is a standard design that can be
taken from chapter 5.1.3. This chapter plus the spare parts drawing Ve_30400 from

© Neuenhauser Kompressorenbau GmbH Page 43 of 44

Revision status: 17 - Subject to technical modifications -

 Operating Instructions – Pressure Equipment and Accessories

9 Appendix Hazardous Material Declaration

Drawings (cross section drawings, spare part drawings):

Drawings, manufacturer documents, operating instructions, suppliers:
The documents listed in this part of the appendix have been drawn up by the
Arrangement of valve heads:
respective manufacturers. Therefore, NEUENHAUSER KOMPRESSORENBAU GMBH
Ve_30401 Valve head DN 38 assembly
does not offer any guarantee for completeness and accuracy!
Ve_30402 Valve head DN 50 assembly
Ve_20654 Safety valve type 2108
Ve_30400 Valve head DN 80 assembly Operating instructions
Ve_23015 Safety valve LESER type 438
Spare part drawings: Operating instructions
Ve_30063 NK angular valve DN 8, PN 63 Zu_30715/Zu_30962 Ball-float traps type BR630
Ve_30141 NK air relief valve DN 8 Operating and assembly instructions
Ve_30244 NK angular valve DN 16 Zu_31671 Ball-float traps type 12 CO PN63
Ve_30383 NK angular valve DN 20 Installation and operating instructions (type 12 CO PN63, 32U)
Ve_30321 Pressure gauge with bolts Zu_30876 Ball-float traps type EF-1281
Operating instructions
Ve_30152 Assembly valve inset DN 12
Operating instructions / data sheet Pressure transmitter type ECTN 8477
Ve_30156 Assembly valve seat DN 12 Declaration of conformity
Ve_30133 / Ve_30157 Assembly valve inset DN 18 Data sheet / operating instructions Electrical pressure switch with display
Ve_30137 Assembly valve seat DN 18 type PSD-30/31
Data sheet / operating instructions Pressure gauge with bourdon tube type
Ve_30123 Assembly valve inset DN 38
213.53
Ve_30103 Assembly valve seat DN 38
Ve_30146 Assembly valve inset DN 50
Ve_30160 Assembly valve seat DN 50 Other appendices, project specific documents:
Ve_30116 Assembly valve inset DN 80 /
Ve_30107 Assembly valve seat DN 80

Analysis of the dangers and risks

Lubrication oil recommendation

REACH regulation
© Neuenhauser Kompressorenbau GmbH Page 44 of 44

Revision status: 17 - Subject to technical modifications -

 10 11 12 13 14 15 16
210 Sicheche~tsventil Type 438. pe 33 bar Einstelldcuck und Art1kel-Nr. gem a! Ve_23015 0112867 1.40
safety valve type 438. pe 33 bar set pressure and art1cel-no. ace. to Ve_23015
200 1 Sicheche~tsventil ON 8.PN 30.G 112 Einstelldcuck und Art1kel-Nr. gem a! Ve_20654 0055390 0.27
safety valve set pressure and art1cel-no. ace. to Ve_20654
A A
bel Focm AIEl 190 Zyl-Schraube m SchL1tz M6 X 8 0059229 0.01
CIEI slotted cheese-head screw
Vecschlussschcaube 5 112 bel Form BIEI
180 Zyl-Schraube m SchL1tz M5 X 0059228 0.01
valve at form AIEl
slotted cheese-head screw
valve at focm CIEI
Entl uftungsvent i L I form AE. BE. CEl at form BIEI 170 Eckventil ON B. G 112 G 0051113 0.40
ansonsten Verschlussschraube G 112 QJ60 angular valve 0 N B. PN 63.
a 11-rel1ef valve
otherwise plug 5 112 160 Rundstahlrohr nahtl 12.0x2.0/1.4301 0054432 0 .Q7
drain pipe
150 Entl Oftungsventil ON B. Ve_30141 0059655 0.31
Vent1ng valve ON B, G
140 0 ichtr ing Focm A 0059125 0.00
gasket r 1ng
130 ON 38, G 1 112, L=160 galvan1sch verz 1nkt 0059700 0.57
galvanized
120 zum Anschl 1eBen des Entw iisserungsrohrs 0059224 0.04
0
c- for connection of the dra 1n p 1pe
110 zum Anschl 1eBen des Entw iisserungsrohrs 0058696 0.04
foe connection of the drain p1pe
0 100 Sicherungsblech fUr V-eins DN38 Ve_20134 0059405 0.02
Lock 1ng plate
~FullventiLDN 18 90 Sechskantmutter M20 X 2 0054208 0 .OB
filling valve hexagon nut M20x2
so Ovalflansch f. Vk. ON 38. ungeb. Bohrung gem aB Bestellung, max. 5 1 112 005962B1.84
Outlet flange for valve head ON 38. bl1nd de~LL1ng ace. to order. max. 049. 112
70 0 ichtr 1ng Focm A SOxS7x2 0059128 0.01
---tA 60
gasket r1ng
St1ftschraube 1,2Sd
DIN 7603
M20 X 2 X 55 0059233 0.19
stud
so VentllSIIZ ON 3B. komplett detaillierte Zeichnung, Ve_30103 0057345 0.06
valve seat ON 38. complete detailed drawing
40 VentllSIIZ ON 18 detaillierte Zeichnung Ve_30137 0057610 0.10
valve seat ON 18 deta1Led drawing
S'o
30 Vent1Le1nsatz ON 38. komplett deta~LL1erte Ze~ehnung Ve_30123 0059493 2.30
Valve 1nsect ON 38, complete deta1Led drawing
~
20 Vent1Le1nsatz ON komplett deta~LL1erte Ze~ehnung Ve_30133 00594 74 1.16
0 valve 1nsert ON complete deta1Led draw~ng·
10 Ventilkopfgehause ON 38 0059705 11.84
Valve Head Cas1ng ON 38
0
c- Pos. Stk Benennung Abmessung/Bemer kung Art. Nc. Gewich
pos. pes description dimens 1on/remark art. no. we 1ght
IKgl

Manometer absperrvent L
1

pressure-gauge shut-off valve

Form AE.
Zusatz T' bedeutet
Entl uftungssvent il (Pos. 1501
zum Entl Uften der Anlassle 1tung
IDarstellung be1dec Typen. nuc zwISChen Beh aLter und Motor.
safety valve
(both types are shown, only one connect1onl

Startluftvent1L ON 38
start 1ng-a 11 valve

Anschlussflansch fUr d1e Startluftle1tung

(Bohrung gema! Bestellung max. o49, G 1 1121
connection flange for start1ng-a1r pipe
Ide ILL 1ng ace. to or dec max. o49, G 1 1/21

76 76

204
Entwasserungsrohr (nur bei Form A(Ell
231 dra~n pipe (only w1th focm AIEII 20.04.2016 T.Wegner
Index Anderung Datum Name
PC 50 Datum Name Werkstoff-Daten Bez.
Gez. ~o 04.~016 T.Wegner Bez. 10 IN ENJ NEUENHAUSER

A-A
Gepr. 1J.o5.2016T.Wegner Halbzeug-Daten
Status Fre1gegeben Halbzeug

f-~"===---iDIN-Norm
I
6276
Halbzeug-Nr.

NC Art.Nr.
KOMPRESSORENBAU

Z.Nr.
Index 0 Blatt-Nr .. 1
Ersatz fOr·
Ersetztdurch
VE_30401-0-0 10 11 16 A1
 10 11 12 13 14 15 16
210 1 S~eheche~tsventil Type 438, pe 33 bar Einstelldcuck und Art1kel-Nc. gem a! Ve_23015 0112867 1.40
safety valve type 438, pe 33 bar set pressure and art1cel-no. ace. to Ve_23015
be 1 Form A 200 1 S~eheche~tsventil ON 8, PN 33, G112 Einstelldcuck und Art1kel-Nc. gem a! Ve_20654 005534 7 0.27
bei Form C safety valve ON 8, PN 33, G 112 set pressure and art1cel-no. ace. to Ve_20654
A Vecschlussschraube G 1/2 be~ Form B und 0 A
190 Zyl-Schraube m Schlitz M5 X 6 0059228 0.01
valve at form A slotted cheese-head screw
valve at form C
at form B and 0 180 Rundstahlcohr nahtl 12,0x2,0/1.4301 0054432 0.07
060 drain pipe
Hilfsluftvent1l ON 12
fehlt bei Form D 170 Zyl-Schraube m Schlitz 0059229 0.01
aux 1Liar-a1r valve ON 12 slotted cheese-head screw
missing at form 0
160 Eckvent1l ON 8, G 112 G 0051113 0.40
angular valve 0 N 8, PN 63,
150 0 ~ehtc 1ng Form A
gasket r 1ng
140 Sechskantmutt er M20 X 2 0054208 0.08
hexagon nut M20x2
130 Ovalflansch f. Ventilkopf ON 50 Bohrung gem ilB Bestellung: max. o61 I G 0060238 2.07
flange f. valve head 0 N SO dr1Ll1ng ace. to order max. 061 I G 2
120 Gewindecohc ON 50. G2 galvan1sch verz 1nkt 0059692 2.51
N
N
splash p1pe ON SO, G2 galvanized
110 Vee schcaubung XS-121 -A3C zum Anschl eBen des Entw iisserungsr 6hrs
1 0059224 0.04
cap screw XS-121 -A3C foe connection of the de a 10 p 1pe
100 OPR 12-L/S zum Anschl eBen des Entw iisserungsr 6hrs
1 0058696 0.04
Clamp 1ng r 1ng foe connection of the dca10 p1pe
90 D1chtr 1ng Form 6Sx7 4x2 ,5 005454 7 0.02
gasket r 1ng DIN 7603
80 St 1ftschcaube 1.2Sd M20 X 2 X 55 0059233 0.19
stud
---FOllventil ON 18 70 Ventils1tz ON SO, komplett deta1Ll1erte Ze1chnung: Ve_30160 0059354 0.00
fill 1ng valve valve seat ON 50, complete detailed drawing,
60 Ventils1tz ON 18 detallllecte Ze~ehnung, Ve_30137 0057610 0.10
valve seat ON 18 detailed drawing,
50 Ventile 10satz ON komplett detailliecte Zeichnung, Ve_30157 00594 74 0.00
valve insert ON complete detailed drawing
40 Ventils 1tz ON komplett deL:Jillierte Zeichnung Ve_30156 0059590 0.00
valve seat ON complete deta1Led drawing
30 Ventile 1nsatz ON komplett deta1LL1erte Ze1chnung Ve_30152 0059562 0.00
valve insert ON complete deta1Led drawing
0
e- 20 Vent ile 1nsatz DN 50, komplett deta1LL1erte Ze1chnung Ve_30146 0059444 0.00
N
Valve insect ON 50, complete deta1Led draw~ng·
10 Ventilkopfgehause ON 50 Standard 0059853 21.48
valve head casing ON SO
Pos. Stk Benennung Abmessung/Bemer kung Act. Nc. Gewich
pos. pes description dimens 1on/remark art. no. Weight
IKgl

anometer-Absperrvent il
pressure-gauge shut-off valve

S1cherhe 1tsvent1L
[Darstellung be1dec Typen, nuc e~n Anschluss)
safety valve
(both types are shown, only one connection)

393

Stactluftvent1l ON SO
start 1ng-a 1r valve

Anschlussflansch fOr d 1e Stactluftle~tung

!Bohrung gema! o61, G 21
connection flange pipe
[drilling ace. to order, max. o61. G 21

~
N

R 2
75 75

232

Entw assecungscohr lnuc Form AI

de a 1n pipe (only form AI
266

21.04.2016 T.Wegner
Index Anderung Datum Name
PC 50 Datum Name Werkstoff-Daten Bez.
Gez. Z1.04.Z016T.Wegner Bez.IOINENl NEUENHAUSER
Gepr. 1l.05.2016T.Wegner Halbzeug-Oaten
Status Fre1gegeben Halbzeug

f-~"===---iDIN-Narm
I
Halbzeug-Nr.

NC Art.Nr.
KOMPRESSORENBAU

F-F Z.Nr.
Index 0 Blatt-Nr .. 1
Ersatz fOr·
Ersetztdurch
VE_30402-0-0 10 11 16 A1
 10 11 12 13 14 15 16
220 1 Sichecheitsvent1L Type 438, pe ll bar Einstelldcuck und Actikel-Nc. gemaB Ve_2l01S 0112867 1.40
safety valve type 438, pe ll bar set pressure and article-no. acc. to Ve_2l01S
S icherheitsvent il
(Darstellung beider Typen, nur ein Anschluss) 210 1
A safety valve
(both types are shown, only one connection)

1,S, 0 IN 16271 OOS4SS2 0. 90

OOSS319 0.04

OOS9670 4.38

160 8 Skt -Schraube M20 X SO OOS2191 0.4

hexagon head screw
----_Hilfsluft- I Typhonventil ON 16 b1s ON 20 150 1 Vocschwe i Bflansch DN 80, PN 64 0054549 6.52
Dichtflache/face type 8 lEN 1092-11
auxiliary-air- 1 tyfon-valve
140 1 Dichtung 138 x 2 asbestfre i 0059677 0.15
gasket 136 x x 2 non-asbestos
130 1 Sicherungsblech fUr V-eins DN38 Ve_201l4 0059405 0.02
Locking plate
120 1 Zyl-Schraube m SchL1tz M6 X 8 0059229 0 .Q1
slotted cheese-head screw
110 1 Vent1Leinsatz ON 38, komplett del a 1LL i ecte Ze ~ehnung, Ve_l012l 0059493 2.30
Valve 1nsect DN lB, complete deta1Led drawing·
~FOllvent1l ON 38
f1ll1ng valve 100 1 Vent1Leinsatz ON 80, komplett del a~ LL i ecte Zmhnung, Ve_l0116 0059446 0.00
valve 1nset ON 80, complete deta1Led drawing:
90 Vent1Lsitz ON 80, komplett del a 1LL i ecte Zmhnung, Ve_l0107 005944 7 0.00
valve seat DN 80, complete detailed drawing,
so Vent1Lsitz ON lB. komplett del a~ LL i ecte Zmhnung, Ve_30103 0057345 0.06
valve seat DN 38, complete detailed drawing,
70 Vecschcaubung GE-R-ED mont~ert in FOLLanschluss 0435449 0.00
screw cap mounted in filling connection
60 Dichtkantc 1ng 0054136 0.01
DKI P 112
SO komplett del a 1LL i erte Zmhnung, Ve_303Bl 1088500 ].30
complete Ventil I valve ON 16, Ve_l0244
40 G 112 G 112 I ur Manometer Pos. 190 " 200 0054592 0.21
pulsation damper for pressure gauge pos. 190 + 200
30 Dichtring Form A 21x26x1 ,S 0059125 0.00
gasket ring DIN 7603
20 Dichtring Form llxl9x2 0056297 0.00
gasket ring DIN 7603
--Hilfsluft- I Typhonventil ON 16 bis ON 20 10 Ventilkopfgehause ON 80 m1t 2x G 1/2, 2x G 1 0059445 110.54
auxiliary-air- I tyfon-valve valve body
Pos. Stk .Benennung Act. Nc. Gewich
pos. pcs.description art. no. we1ght
IKgJ

Manometer
pressure gauge Startluftvent i l 0 N 80
starting-air valve

Anschlussflansch fOr die Startluftle itung

connection flange for starting-air p1pe

C)
a::J
a::J

165 165

354

NEUENHAUSER
Gepr.
Status
Halbzeug-Nr.

NC Art.Nr.
KDMPPESSDPENBAU

A-A Z.Nr.
lndeK 0 Blatt-Nr •. 1
Ersatz fOr·
Ersetztdurch

VE_30400-0-0 10 11 16 A1
 1 2 3 4

-I 1- Gill,
-j A

co

~~
C)
'-0
&

- 16 -1 N
N [--
N B
3 1
l/)
3
l/)

- 111 -
(ge offnet /open)

Unterlegsche i be I washer Ms 0050243

Sechskantmutter I hexagon nut Ms 0058880 D

Hutmannschette I cap- type gasket Perbunan 0055412

4 Handrad I hand wheel GTW -40 0055930

3 Oberwurfmutter I cap nut Ms 0055426

2 1 I Ventilsp1ndel mit 0 ichtungsscheibe Ms + Nylon 0055406

valve soindle with sealino d1sc
Toleranzen fur Schwe i Bbaugruppen Geh iiuse I housing Ms
EM I SO 13920-D
Allgeme i ntoleranzen Pos' I Stuck I Benennung W e1 k s to ff Alt-Nr.
DIM ISO 2768-mK pos. piece description material art. no. I I E
Ersatz fur Ve_21024 01.03.2016 T.Wegner
0 01.03.2016 T.Wegner
Index I Anderung Datum Name
PC SO Datum
1 Name IWerkstoff -0 aten
1 Bez.: Ns
Gez. lo1.0l.2016IT.Wegnec INr. Bez.IDINEN) Ns NEUENHAUSER
Gepr.
Status

~--~S~ch_uLtz-v-ec_m_e~ck--n-ac~h--~
DIN ISO 16016 beachten!
Halbzeug-0 aten
Halbzeug:
DIN-Norm:
EN-Norm:
Halbzeug-Nr.:

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON 105941) 604-0
TELEFAX 105941) 604-202
e-mail NK©neuenhauser.de
Na Sstab Art. Nr. 0051113 I F
Ezk vent i l DN 8, G 1/2 - G 114 z. Nr. Ve_30063
11
angular valve ON 8. PN 63. brass Index 1 Blatt -Nr.
G 1/2 male - G 114 female Ersatz fur Ve_21024
Ersetzt durch
VE_30063-0-1
 1 I 2 I 3 I 4

A
[-- [--
N N
ffl
f--
3 3
CXJ
l/J l/J

f -

1
,--- f--
r-

~
[I
t---
\

-o----
t---
_" C>

It-
-
1- ----- - r---'-0
~

~
f--
_v-
I f-- B
r-
L_
t---

14
l
t---
'\.___j -

83
(ge offnet I open)

1 s 2

7
(j
12

7 1 Unterlegscheibe I washer Ms 0050243

6 1 Sechskantmutter I hexagon nut Ms 0058880 D

3 5 1 Hutmannschette I cap- type gasket Perbunan 0055412
6 4 1 Handrad I hand wheel GTW -40 0055930
4
3 1 Oberwurfmutter I cap nut Ms 0055426 -

2 1 Ventilspindel mit D ichtungsscheibe Ms + Nylon 0055406

valve spindle wllh seal1nq d1sc
Toleranzen fur Schwe i Bbaugruppen 1 1 Geh iiuse I housing Ms 0055424
EN I SO 13920-D
Allgeme intoleranzen Pos. stuck Benennung W erkstoff Art-Nr.
DIN ISO 2768-mK pos. piece description material art. no. E
1 Textfeld-Anpassung 12.04.2016 T.Wegner
0 12.04.2016 T.Wegner
Index Anderung Dalum Name
p[ so Datum Name Werkstoff -0 aten Bez .: Ms
Gez. 12.04.2016 LWegnec Nr .: Bez.IDINEN) Ns NEUENHAUSER
~~
-

Gepr. 12.04.2016 LWegnec Halbzeug-0 aten Halbzeug-Nr .: KnMPRISSnRINnAI

Status Fceigegeben Halbzeug: I 0-49828 NEUENHAUS
TELEFON 105941) 604-0
DIN-Norm: TELEFAX 105941) 604-202
Schutzvecmeck nach e-mail NK©neuenhauser .de
DIN I SO 16016 beachten! EN-Norm
Na Sstab Art. Nr. OOS96SS F
Entl uftungsvent i l ON 8, G 112 Z. Nr. Ve_30141
11
Vent1ng valve ON 8, G 112 Index 1 Blatt -Nr. 1
PN 42, Messing
PN 42, brass Ersatz fur Ve_21014
Ersetzt durch
VE 30141-0-1 I
 2 3 4 5 6 7 8

A A
60 10 30

ERMETO GE22LRCF
L pipe C/;22

54

20

so 40
D

a rox, 200 (o ened)

60 Verschraubung screw cap OOS8691
so Zyl-Schraube m Schlitz slotted cheese-head screw OOS9228
40 S1cherungsblech SW 41 Lock 1ng plate OOS9103
30 Vent1Le1nsatz ON 18, komplett valve 1nset ON 18. complete OOS9474
20 Vent1ls1tz ON 18 valve seat DN 18 OOS7610
10 Vent 1Lgeh ause 0 N 16 valve case DN 16 OOS9643
Pos. Stk. Benennung description Art. Nr.
E pos. piece art. no. E
Bez. I Nodifikat1onen OS .OS .201S Bhs
0 07.12.2007 B uschers
Index Anderung Datum Name
PC Datum Name Werkstoff-Daten Bez.
Gez. 07.12.2007 Buschm Nr. Bez. 10 IN EN)
Gepr. o5.o5.2015 Bhs Halbzeug-0 aten Halbzeug-Nr.
Status Fre igegeben Halbzeug
f------=-~------c---c--- 0 I N- Norm
Schutzvecmerk nach
DIN ISO 16016 beachten! EN-Norm:
F uGu-t hIed d5 dIe d[ [ . t 0 I s0 2 28 Ma Bstab

12 D 1mension tolerances ace. to ISO 2768-mK Vent1l ON 16. G 1 - G 3/4

W e 1ght 1s calculated . true we 1ght m1ght be vary. 11
valve with pipe coupling
m1t Verschraubung GE 22-PLR
we 1ght: approx. 3.5 kg (empty)
VE_30244-0-1 2 3 4 5 6 7
 2 3 4 5 6 7 8

A 54 A

33
10
30

20 40
3
l/l
50

a roxo 200
D (ge Offnet I open) D

SO Zyl inderschraube m Schlitz N S X 6 OOS9228 0.01

slotted cheese head screw
40 S1cherungsblech SW 41 fur Vent 1le 1nsatz DN 18 OOS9103 0.01
locking plate
30 Ventileinsatz ON 18, komplett Ve_301B7 0059474 0.00
valve insert ON 18, complete
20 Ventilsitz ON 18 Ve_20984 OOS7610 0.10
valve seat 0 N 18
10 Vent ilgeh ouse 0 N 20 Ve_303B2 1088499 1.87
valve housing
Pos. Stk. Benennung Abmessung/Bemerkung Art. Nr. Gew 1cht
E pos. p1ece description d 1mens 1on/remark art. no. weight E
[Kg]
Tabelle aktual1 s 1ert 23 .OS .2016 T.Wegner
0 12.04.2016 T.Wegner
Index Anderung 0 alum Name
PC SO 0 alum Name W erkstoff -0 aten Bez .:
f----+--~--
Gez. 12.04.2016 T.Wegner Nr.: Bez. 10 IN EN): NEUENHAUSER
Gepr.
f----+--~--
Status
2l.OB.2016 T.Wegner

Freigegeben

f------::-~------c--c--- 0 I N- Norm
Schutzvermerk nach
D1N 1so 16016 beach ten!
Halbzeug-Daten
Halbzeug:

EN-Norm:
Halbzeug-Nr .:

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON IOS941) 604-0
TELEFAX IOS941) 604-202
e-mail NK©neuenhauser .de
F Na Bstab Art. Nr. 108BSOO F
Threads acc" to I SO 228-1 Toleranzen fur Schwe Sbaugruppen
1
Venti l DN 20, komplett Z. Nr. Ve_30383
Weight is calculated, true weight m1ght be vary" EN I SO 13920-D 11
valve DN 20, complete Index 1 Blatt -Nr. 1
Weight: approx" 3,3 kg Allgeme ntoleranzen
1
Ersatz fur
DIN I SO 2768-mK Ersetzt durch
VE_30383-0-1 2 3 4 5 6 7 8 A3
 1 2 3 4 5 6 7 8

A A

B B

0'-
N
~

sw 14
Ln
0'-
[ [
sw 19
0'-
.....j- sw 17

D D
37.5 12
40 EW 08LREDOMD [ F [f ERMETO W inkel-Stutzen mit Dichtkegel 0431540 0.08
adjustable elbow coupling approved
30 MAVE08LRCF [f ERMETO Manometerverschraubung 0431536 0.06
pressure gauge fitting approved
20 1 Dichtkantr ing DKI ERMETO DKI R 1/4 0058739 0.00
ED edge sealing ring for MAVE DKI approved
10 Glyzer in-Manometer 0-40 bar 9 63, G 114 0054579 0.22
pressure gauge. glycerine
I Pas. Stk. Benennung Werkstoff Abnahme DIN Abmessung/Bemerkung Art. Nr. Gewicht
E pos. piece description material inspect ion dimension/remark art. no. weight E
EN10204 [Kg]
1 Zeichnung angepasst 14.03.2016 T.Wegner
h ~ r-
Y/ =-----~ f-- .---- 0 19.02.2010 Scheppm.
tl
If
-- -
Index Anderung Datum Name
PC so Datum Name W erkstoff-Daten
l\ -~- //le-- F===
~
Gez. 19.02.2010 ScheDDm. Nr .:
Bez.:
Bez. (0 IN EN): NEUENHAUSER
N ""' v ~

Halbzeug-Nr .: KOMPRESSORENBAU
~
L--
~ CJ'. D-49828 NEUENHAUS
~ TELEFDN (05941) 604-0
3 3 TELEFAX (05941) 604-202
V1 l/) 3 e-mail NKftneuenhauser .de
V1
F
Toler anz en f ur Schw ei Bbaugr upp en Glyzer in-Manometer 0 63, 0-40 b
EN ISO 13920-D 11
pressure gauge
G 1/4. mit Verschraubung
Allgem e in toler anzen Ersatz fur: Ve_23014-Blatt1
DIN ISO 2768-mK Er set zt durch:
VE_30321-0-1 2 3 4 5 6 7 8 A3
 2 3 4 5 6 7 8

A A

100

B B
A A
1:2
Toleranzen fur Schwe i Bbaugruppen
EN I SO 13920-D
Allgeme intoleranzen
c DIN I SO 2768-mK
Q)
0_
140 Packungsschnur PTFE 3x3 0055335 0.00
0 Valve pack 1ng
~
3x3x400 mm [
[ N +- 130 Grundr1ng fur Venllle1nsatz ON 12 0059S39 0.00
~ Q)
base ring
~
c
+- 120 Oberwurfmutter G 314 fur V-e1ns 0059556 0.08
+- cap nut G 3/4 for valve 1nset 0 N 12
eC>
Q)
110 Stopfbuchse L=22 0059509 0.03
Dl packing sleeve

sw 32 100 S1cherungsblech SW 32
Locking plate
0059109 0.00

90 D1chtr 1ng Form A 7603 A 30x36x2 0059126 o.ora

gasket r 1ng
BO Se ch sk an tm utter 934 0 IN 934 - M 12 0093168
hexagon nut M12
70 Sche 1be Form A 125-1 A 10.S gaLZn 022S248 0.00
washer
60 Handrad d=100 0055929 0.00
D hand wheel D
so Gew indesllft m Kegelk+Schl 551 Gewindesllft - M 4 X 3 0059216
sw 32
40 10
slotted grub screw with cone point
Kugel d=3 0059115 0.00
ball d=3 1.3541
30 Vent ilkegel fur Vent ile insatz DN 12 0059516 0.03
valve cone for valve inset 0 N 12
20 Ventilspindel ON 12 0059504 0.16
valve sp 1ndle
10 Sp 1ndel f uhrung Vent 1Le 1nsatz 0 N 0059526 0.22
G 7/B spindle guide for valve 1nset ON 12
Pos. Stk. Benennung Abmessung/Bemerkung Art. Nr. Gew 1chi
DIN
pos. p1ece descr ipt 1on d 1mens 1on/remark art. no. weight
E [Kg] E
Taballe aktual 1s 1ert 23.08.2016 T.Wegner
2 Ze i chnung erg anzt 13 .OS .2016 T.Wegner
Anpassungen 22.03.2016 T.Wegner
Index Anderung 0 alum Name
PC SO 0 alum Name Werkstoff -0 aten Bez .:
r---~----~----~
Gez. 22.03.2016 T.Wegnec Nr.: Bez. ID IN EN): NEUENHAUSER

A-A
Gepr.
Status
2l.OB.2016 T.Wegnec
r---~----~----~
Fceigegeben
Halbzeug-Daten
Halbzeug:
r-----=~c------c------c---~ 0 I N- Norm
Schutzvermerk nach
D1N 1so 16016 beach ten! EN-Norm:
Halbzeug-Nr.

( KOMPRESSORENBAU
0-49828 NEUENHAUS
TELEFON 105941) 604-0
TELEFAX 105941) 604-202
e-mail NK©neuenhauser .de
F Ma Bstab Art. Nr. OOS9562 F
Ventileinsatz ON 12, komplett Z. Nr. Ve_301S2
75
valve 1nsert ON 12, complete Index Blatt -Nr.
Ersatz fur
Ersetzt durch
VE_301S2-0-3 2 3 4 5 6 7 8 A3
 1 I 2 I 3 I 4
025
1- - I ~
~ A
I
I

~ I ~

~ 'i/r_~
I

I
1
I I
' /,
II
-
!

I 0
~~
I
~
~ -

N ~

r----------
~ ~~
~
r----------
0
~
r----------
B
I

M20k1.5
I
A-A
I -

I
I

I
I

J
I

I
I

I \ [
I

---+--- I

~'::,,~,;;/
-

~~~ I

~~~ ~~

sw 11
Toleranzen fur Schwe I Sbaugruppen
u~ ISO 13920-D
trz7l13 D

Allgeme ntoleranzen
D I ~~ ISO 2768-mK
1

6:5
30 1Stutmng fur Vent1ls1tz D~~ 12 0059575 0.00
supporting ring for valve seat D~~ 12
20 1 Dichtr1ng fur Ventilsitz D~~ 12 0059581 0.01
sealing r1ng for valve seat D~~ 12
10 1 Verschraubung f. Ventils1tz D~~ 12 D I~~ U~ 10088-3 0059566 0.03
screw connection for valve seat D~~ 12
Pos. Stk. Benennung D I~~ Abmessung/Bemerkung Art. ~~r. Gew 1cht
pos. piece desmpt ion d 1mens 1on/remark art. no. weight
IKgl
2 Tabelle aktual1 s i ert 24.08.2016 T.Wegner E
1 Anpassungen 22.03.2016 T.Wegner
0 22.03.2016 T.Wegner
Index Anderung Datum ~~a me

p[

Gez.
Gepr.
Status
so Datum ~~a me
22 .OJ .2016 T.Wegnec

24.08.2016 T.Wegnec

Fceigegeben
W erkstoff -0 aten
~~ r . :

Halbzeug-0 aten
Halbzeug:
D I ~H~orm:
I
Bez .:
Bez.IDI~~U~J

Halbzeug-~~r .: N( ~~ EUE~m AU SER

KnMPRISSnRrlmAI
D-49828 NEUENHAUS
TELEFm~ 1059411 604-0
-

TELEFAX 1059411 604-202

Schutzvecmeck nach e-mail ~~K©neuenhauser .de
D I~" I SO 16016 beachten! E~~-~~orm

Ma Bstab Art. ~~r. 0059590 F

Ventilsitz m~ 12, komplett Z. ~~ r . Ve_30156
s2 valve seat D~~ 12, complete Index 2 Blatt -~~r. 1
Ersatz fur Ve_21044
Ersetzt durch
VE_30156-0-2 I
 2 3 4 5 6 7 8

A
~ )50 A

1/E:B.
~;:: A A

B B

c
Q)
D_ Toleranzen fur Schwe Bbaugruppen
1

0 EN ISO 13920-D
~
1'1 -+- Allgeme ntoleranzen
1

0 Q)
~ c DIN ISO 2768-mK
-+-
-+-
'C) sw 41 1SO S1cherungsblech SW 41
locking plate
OOS9103 0.00
Q)
140 D 1chtr 1ng Form A 7603 A 42x49x2 OOS9124 0.01
Dl
gasket r 1ng
[ [
130 Sechskantmutter N10 DIN 934 nach AD 2000 W7 0338679 0.01
hexagon nut
120 Sche 1be Form A 12S-1 A 10 .S galZn 022S248 0.00
washer
110 Handrad d=12S OOSS928 0.20
hand wheel d=12S
100 Packungsschnur PTFE SxS SxSx700 mm OOSS32S 0.00

sw 41-------1 90
cord PTFE SxS
Stopfbuchse L=22 OOS94 71 0.06
tamp 1ng sleeve
80 Ob er wur fmut te r L=2S OOS9473 0.14
cap nut
70 Grundr1ng fur Venllle1nsatz ON 18 d=2Sx4 OOS9468 0.01
base ring for valve insert ON 18
60 Gew indesllft m Kegelk+ I nnenskt 913 Gew indest 1ft DIN 913 - N S X 4 galZn 0081920 0.01
0 hexagon socket set screw w1th flat po1nt 0
so 11 Kugel 04 RB-4 RS OOS4S28 0.00
ball 04 RB-4 RS
M42xt5---- 40 Vent1lkegel ON 18 Ve_20904 OOS94S2 0.07
valve cone for valve insert DN 18
30 Vent ilsp indel fur Venllle1nsatz ON 18 OOS94SO 0.21
valve spindle for valve insert ON 18
20 Schutzrohr 032x1.0 xl=29 OOS946S 0.02
Protective pipe for valve insert ON 18
10 Sp 1ndel f uhrung 0 N 18 DIN EN 1002S-2 N42x1.S I N33x1.S OOS9463 0.48
spindle guide for valve 1nsert ON 18
Pos. Stk. Benennung DIN Abmessung/Bemerkung Art. Nr. Gew 1chi
pos. p1ece descr ipt 1on d 1mens1 on/remark art. no. weight
E [Kg] E
2 Tabelle aktual1s1 ert 24.08.2016 T.Wegner
Anpassungen 21.03.2016 T.Wegner
0 21.03.2016 T.Wegner
A-A Index Anderung Dalum Name
PC SO Dalum Name Werkstoff -0 aten Bez .:
~---+----~----
Gez. 21.03.2016 T.Wegnec Nr.: Bez. ID IN EN): NEUENHAUSER
Modell fur Venti lkopf 0 N 38 I

we1tere Modelle des Vent1leinsatzes ON 18:

~G---'ep_r_.+2_4._os_.2_01_[6_T._w_eg_ne_c Hal bz eu g- Date n
Status Fceigegeben Halbzeug:
~----=-__[__ _ _ _ _ _ _ _-----j
Schutzvermerk nach
D1N 1so 16016 beach ten!
D I N- Norm
EN-Norm:
Halbzeug-Nr .:

( KOMPRESSORENBAU
0-49828 NEUENHAUS
TELEFON IOS941) 604-0
TELEFAX IOS941l 604-202
e-mail NK©neuenhauser .de
F ArL Nr. OOS9474 F
Ve_30157 fur Venti lkopf 0 N 50 Na Bstab
Ventileinsatz ON 18, komplett Ve_30133
Ve_30187 fur NK-Vent1l ON 16 bisON 20 valve insert ON 18, complete
Z. Nr.
6s Index 2 Blatt -Nr.
Ersatz fur
Ersetzt durch
VE_30133-0-2 2 3 4 5 6 7 8 A3
 2 3 4 5 6 7 8

A A

B B
A A
2:5
c
Q)
D_
2:5 Toleranzen fur Schwe Bbaugruppen1

0 EN I SO 13920-D
~
iYl -+-
C) Q)
Allgeme ntoleranzen
1

~ c DIN I SO 2768-mK
-+-
-+- 150 S1cherungsblech SW 41 0059103 0.01
eC>
locking plate
Q)
Dl sw 41 140 D 1chtr 1ng Form A
gasket r 1ng
7603 A 42x49x2 0059124 0.01
[ [
130 Sechskantmutter M10 DIN 934 nach AD 2000 W 7 0338679 0.01
hexagon nut
120 Sche 1be Form A 125-1 A 10.5 galZn 0225248 0.00
washer
110 Handrad d=12S 0055928 0.20
hand wheel d=125

sw 41------v 100 Packungsschnur PTFE SxS

cord PTFE SxS
SxSx700 mm 0055325 0.00

90 Stopfbuchse L=22 0059471 0.06

tamp 1ng sleeve
80 Ob er wur fmut te r L=25 00594 73 0.14
cap nut
70 Grundr1ng fur Venllle1nsatz ON 18 d=25x4 0059468 0.01
base ring for valve insert ON 18
60 Gew indesllft m Kegelk+ I nnenskt 913 Gew indesllft DIN 913 - M 5 X 4 galZn 0081920
0 hexagon socket set screw w1th flat po1nt 0
M42 X1 s________,_
0
so 11 Kugel 04 RB-4 RS 0054528 0.00
ball 04 RB-4 RS
40 Vent1lkegel ON 18 Ve_20904 0059452 0.07
valve cone for valve insert DN 18
30 Vent ilsp indel fur Venllle1nsatz ON 18 0059450 0.21
valve spindle for valve insert ON 18
20 Schutzrohr 032x1.0 xl=29 0059465 0.02
Protective pipe for valve insert ON 18
10 Sp 1ndel f uhrung 0 N 18 DIN EN 10025-2 N42x1.5 I M33x1.5 0059463 0.48
spindle guide for valve 1nsert ON 18
Pos. Stk. Benennung DIN Abmessung/Bemerkung Art. Nr. Gew 1chi
pos. p1ece descr ipt 1on d 1mens1 on/remark art. no. weight
E [Kg] E
2 Ze ichnung aktual1s1 ert 24.08.2016 T.Wegner
Anpassungen 21.03.2016 T.Wegner

A-A Index
0
Anderung
21.03.2016
Dalum Name
T.Wegner

PC SO Dalum Name Werkstoff -0 aten Bez .:

~---+----4---~
Gez. 21.03.2016 T.Wegnec Nr.: Bez. ID IN EN): NEUENHAUSER
Modell fur Venti lkopf 0 N SO I
~G---'ep_r_.-J-2_4._os_.2_016__l_T._w_::eg_ne___jc Halbzeug-0 a ten
Status Fceigegeben Halbzeug:
~_ ____L_ _ _ _ _ _ _ _ _
Schutzvermerk nach
D IN-N or m
Halbzeug-Nr .:

( KOMPRESSORENBAU
0-49828 NEUENHAUS
TELEFON 105941) 604-0
TELEFAX 105941) 604-202
e-mail NK©neuenhauser .de
wei tere Modelle des Venti lei nsatzes 0 N 18: DIN I so 16016 beach ten! EN-Norm:
F
F Ve_30133 fur Ventilkopf ON 38 Ma Bstab Art. Nr. 0059474
Ventileinsatz ON 18, komplett Ve_30157
Ve_30187 fur NK-Ventil ON 16 bis ON 20 valve insert ON 18, complete
Z. Nr.
65 Index 2 Blatt -Nr.
Ersatz fur
Ersetzt durch
VE_30157-0-2 2 3 4 5 6 7 8 A3
 1 I 2 3 4

039
I I 0 A
V//a~
I

V///~ I

~ ~~
I

I
I

~
-
-
I
I Q7 ~
N -----j

f
-
- •{ '',,,;10\
-
- Q7
-

I~ 018 J A-A B
M33x1 ,5

-----j

1:1 I
I

Af~ vtA
I [
1-- _ _L_ _ _

I
r)-
~
~
T -----j

sw 17

Toleranzen fur Schwe i Sbaugruppen

E~~ ISO 13920-D
Allgemeintoleranzen
1:1
~ D

D I ~~ ISO 2768-mK
30 1Stutmng fur Ventilsitz D~~ 18 0057621 0.01 -----j

supporting r~ng for valve seat D~~ 18

20 1 D ichtring fur VenlllSIIZ m~ 18 0057620 0.01
sealing ring for valve seat D~~ 18
10 1 Verschraubung D~~ 18 0057617 0.09
screw 1ng
Pos. Stk. Benennung D I ~~ Abmessung/Bemerkung Art. ~~r. Gew 1chi
pos. p1ece desmpt1on dimension/remark art. no. we 1ght
IKgl
E
1 Ze 1chnung aktual1 s i ert 24.08.2016 T.Wegner
0 21.03.2016 T.Wegner
Index Anderung Dalum ~~a me

p[

Gez.
Gepr.
Status
50 Datum
21.03.2016
~~a me
T.Wegnec
24.08.2016 T.Wegnec

Fceigegeben
W erkstoff -0 aten
~~ r . :

Halbzeug-0 aten
Halbzeug:
D I ~H~orm:
I
Bez .:
Bez.IDI~~U~J

Halbzeug-~~r .: N( ~~ EUE~m AU SER

KnMPRISSnRr~mAI
D-49828 NEUENHAUS
TELEFm~ 1059411 604-0
-----j

TELEFAX 1059411 604-202

Schutzvecmeck nach e-mail ~~K©neuenhauser .de
D I~" I SO 16016 beachten! E~~-~~orm

Ma Bstab Art. ~~r. 0057610 F

Ventils1tz D~~ 18 Z. ~~ r . Ve_30137
valve seat m~ 18 Index Blatt -~~r. 1
21 1
Ersatz fur
Ersetzt durch
VE 30137-0-1 I
 2 3 4 5 6 7 8

A A
160

1:5

B B

3:10

Toleranzen fur Schwe Sbaugruppen 1

EN I SO 13920-D
Allgeme ntoleranzen
1

DIN I SO 2768-mK
140 Se ch sk an tm utter 934 M 12 galZn OOS2022 0.02
hexagon nut
[ [
130 Sche 1be Form A 12S-1 A 13 galZn 0072293 0.01
washer
120 D1chtr 1ng Form A 7603 A 6Sx74x2 ,S OOS4S47 0.02
gasket r 1ng
110 S1cherungsblech fur V-eins DN38 nach Ze 1chnung Ve_20134-c -00 OOS940S 0.02
locking plate
100 Flachkopfschraube MS x 6 920 OOS9231 0.00
flat headed screw
90 14 Kugel 04 RB-4 RS OOS4S28 0.00
ball 04 RB-4 RS
80 Packungsschnur PTFE SxS OOSS32S_001 OOSS32S 0.09
cord PTFE SxS
70 Oberwurfmutter DN 38 I DN SO OOS93S6 0.00
cap nut ON 38 I DNSO
60 Stopfbuchse DN38 I DNSO fur Vent 1le 1nsatz OOS9381 0.09
D tamp 1ng sleeve DN 38 I DN SO D
so Grundr1ng ON 38 I ON SO fur Vent 1le 1nsatz OOS9370 0.01
base ring for valve insert ON 38 1 ON SO
40 Handrad d=160 OOSS926 1.16
hand wheel d=160
30 Vent ilkegel fur Vent ile insatz DN 38 OOS9481 0.00
valve cone for valve inset DN 38
20 Ventilspindel ON 38 I ON SO OOS9363 O.S1
valve spindle ON 38 I ON SO
10 Sp 1ndel f uhrung 0 N 38 OOS9487 1.38
spindle guide ON 38

B-B Pos. Stk. Benennung

pos. p1ece descr ipt 1on
DIN Abmessung/Bemerkung
d 1mens1 on/remark
Art. Nr. Gew 1chi
art. no. weight
[Kg] E
E Ze ichnung aktual1s1 ert 2S .08.2016 T.Wegner
2
Modell angepasst 17.03.2016 T.Wegner
0 17.03.2016 T.Wegner
Index Anderung Dalum Name
PC so Dalum Name Werkstoff -0 aten Bez .:
Gez. 17 .OJ .2016 T .Wegner Nr. Bez. ID IN EN): NEUENHAUSER
Gepr.
Status
25 .DB .2016 T .Wegner

Freigegeben

Schutzvermerk nach
DIN I SO 16016 beach ten!
Halbzeug-0 aten
Halbzeug
DIN-Norm
EN-Norm
Halbzeug-Nr .:

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON IOS941) 604-0
TELEFAX 105941) 604-202
e-mail NK©neuenhauser .de
F Ma Bstab Art. Nr. OOS9493 F
Ventile1nsatz ON 38, komplett Z. Nr. Ve_30123
11
Valve insert DN 38, complete Index 2 Blatt -Nr.
Ersatz fur
Ersetzt durch
VE_30123-0-2 2 3 4 5 6 7 8 A3
 1 I 2 I 3 I 4

060
(4o\
A
/~j
I

.------- r/ r1 II I
I

I I vVi1 !30\
1)//)/r
I

I
/l(li
Ill 030
v
N I

/~
-
I

vr
_j- I

v~
~
I
I

f:3 I
I

I
0
Fi:
I
I
038.4 I
I

20 B
050.2
A-A 0
-
I
I
0 0
I

I
I

I
I

--t--

J'" "t
I [
I
I

-T
;

7 10
1
~~I) l -

Q
Q
Toleranzen fur Schwe i Sbaugruppen
E~~ I SO 13920-D ~

Allgeme i ntoleranzen 7:10 D

D I ~~ I SO 2768-mK
40 1Sicherungsring f Bohrung D I ~j 4 72 60 X 2 OOS7342
guard ring 60 x 2. for boring n n1
30 1 Stutmng fur Vent1ls1tz D~~ 38 OOS7334 0.03
thrust ring for valve seat D~~ 38
20 1 Stutmng innen fur Ventilsitz D~j 38 OOS7338 0.01
support ring for valve seat D~~ 38
10 1 D ichtr~ng fur Ventilsitz D~j 38 OOS7337 0.04
sealing r~ng for valve seat D~~ 38
Pos. Stk. Benennung D I~~ Abmessung/Bemerkung Art. ~~r. Gew 1cht
pos. piece desmpt ion d 1mens 1on/remark art. no. weight
IKgl
2 Ze 1chnung aktual1 s i ert 2S .08.2016 T.Wegner E
1 Tabelle aktual1 s i ert 12 .OS .2016 T.Wegner
0 21.03.2016 T.Wegner
Index Anderung Dalum ~~a me

p[

Gez.
Gepr.
Status
so Datum
21 .OJ .2016

25.08.2016
~jame

T.Wegnec
T.Wegnec

Fceigegeben
W erkstoff -0 aten
~~ r . :

Halbzeug-0 aten
Halbzeug:
D I~Hjorm:
I
Bez .:
Bez. ID l~j Uj)
Halbzeug-~jr .: N( ~~ EUE~m AU SER
KnMPRISSnRr~mAI
D-49828 NEUENHAUS
TELEfmj IOS9411 604-0
-

TELEFAX IOS9411 604-202

Schutzvecmeck nach e-mail ~jK©neuenhauser .de
D I~" I SO 16016 beachten! E~~-~~orm

Ma Bstab Art. ~jr. OOS734S F

Ventilsitz m~ 38, komplett Z. ~~ r . Ve_30103
21
valve seat m~ 38, complete Index 2 Blatt -~~r. 1
Ersatz fur
Ersetzt durch
VE_30103-0-2 I
 2 3 4 5 6 7 8

A A

160

B 3:10 B

c Toleranzen fur Schwe i Sbaugruppen

EN I SO 13920-D
Q)
D_ 3:10
0 Allgemeintoleranzen
~ DIN I SO 2768-mK
L-- -+-
1'1 Q)
~ c 140 S1cherungsblech fur V-eins ON38/SO Ve_20134 OOS940S 0.02
[
-+-
-+- r--+---+l_o_ck_in~g~pl_a_te__________________________-+-------r----------------------------r-----+---~1 [

eO 130 0 1chlc1ng Form A 7603 A 78x88x2,S OOS9130 0.02

Q) gasket r 1ng
Dl
120 Se ch sk an tm utter 934 DIN 934 - M 12 0093168 0.02
hexagon nut M12
110 Sche 1be Form A 12S-1 A 13 galZn 0072293 0.01
washer
100 Handrad d=160 OOSS926 1.16
hand wheel d=160
90 Packungsschnur PTFE SxS SxSx700 mm OOSS32S 0.10
cord PTFE SxS
80 Stopfbuchse 0 N38 I DNSO fur Vent 1le 1nsatz OOS9381 0.09
tamp 1ng sleeve DN 38 1 DN SO
70 Oberwurfmutter 0 N 38 I 0 N SO OOS93S6 0.00
cap nut ON 38 I ONSO
60 Grundr~ng ON 38 I ON SO fur Vent 1le 1nsatz OOS9370 0.01
D base ring for valve insert ON 38 I ON SO D
so Gew indesllft m Kegelk+Schl SS1 Gewindesllft - M S X 8 OOS9219 0.00
slotted grub screw with cone point
40 14 Kugel 04 RB-4 RS OOS4S28 0.00
ball o4 RB-4 RS
30 Ventilkegel ON SO Ve_30002 OOS9367 0.31
valve cone 0 N SO
20 Ventilspindel ON 38 I ON SO OOS9363 O.S1
valve spindle ON 38 I ON SO
10 Sp1ndelfuhrung nach Ze 1chnung Ve_20803-a-OO OOS9377 1.89
spindle guide
Pos. Stk. Benennung DIN Abmessung/Bemerkung Art. Nr. Gew 1chi
pos. p1ece descr ipt 1on d 1mens1 on/remark art. no. weight
E [Kg] E
Ze ichnung aktual1s1 ert 2S .08.2016 T.Wegner
2 Sechskantmutter ausgetauscht 13 .OS .2016 T.Wegner
Daten angepasst 21.03.2016 T.Wegner
Index Anderung 0 alum Name
PC so 0 alum Name W erkstoff -0 aten Bez .:
Gez. 21.03.2016 T .Wegner Nr. Bez. 10 IN EN): NEUENHAUSER

A-A
Gepr.
Status
25 .DB .2016 T .Wegner

Schutzvermerk nach
Freigegeben

r-----=-~-------c----c--- 0 I N- Norm
D1N 1so 16016 beach ten!
Halbzeug-0 a ten
Halbzeug

EN-Norm:
Halbzeug-Nr.

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON IOS941) 604-0
TELEFAX IOS941l 604-202
e-mail NK©neuenhauser .de
F Ma Bstab Art. Nr. OOS9444 F
Ventileinsatz ON 50, komplett Z. Nr. Ve_30146
11
Valve nsert DN 50, complete
1

Index 3 Blatt -Nr.

Ersatz fur
Ersetzt durch
VE_30146-0-3 2 3 4 5 6 7 8 A3
 1 2 I 3 I 4

A
0

--I VI
075
I
/u -

I I I I I V 'I
/) I /
N
r--
30
c-- I
r-
~
I
~
f-------- ~
f--------
I
I
rm f--------
~
f--------
f-------- rm I
I 00 f--------
10
B

I. _I
I

050 I
,_ ~

A-A - 065.1
20 -

~
lI

A' '--+ ----+---

I
I

I
I
'A
I

~~)
010

1:2
Toleranzen fur Schwe i Bbaugruppen
E~~ I SO 13920-D
Allgeme i ntoleranzen
1:2 D
D I ~~ ISO 2768-mK
40 1Sicherungsring f Bohrung D l~j 472 7S X 2. S OOS9110 0.02
guard ring 7S x 2 ,S, for boring
30 1 Stutmng fur Vent1ls1tz D~~ SO D I ~j Uj 10305-1 galvan1s1ert I galvanized OOS9348 0.06
supporting ring for valve seat D~~ SO
20 1 Stutmng innen fur Ventilsitz D~j SO galvanisiert I galvanized OOS93S2 0.02
internal support ring
10 1 Dichtr1ng fur Ventilsitz D~j SO 6S.1 x SO x 10.2 mm OOS93SO 0.09
gasket for valve seat D~~ SO
Pos. Stk. Benennung D I ~j Abmessung/Bemerkung Art. ~~r. Gew 1cht
pos. piece desmpt ion d 1mens 1on/remark art. no. weight
IKgl
2 Ze 1chnung aktual1 s i ert 2S .08.2016 T.Wegner E
1 Anpassungen 18.03.2016 T.Wegner
0 18.03.2016 T.Wegner
Index Anderung Datum ~~a me

p[

Gez.
Gepr.
Status
so Datum
1B .03.2016
~jame

T.Wegnec
25 .OB .2016 T.Wegnec

Fceigegeben
W erkstoff -0 aten
~~ r . :

Halbzeug-0 aten
Halbzeug:
D I~Hjorm:
I
Bez .:
Bez. ID l~j Uj)
Halbzeug-~jr .: N( ~~ EUE~m AU SER
KnMPRISSnRr~mAI
D-49828 NEUENHAUS
TELEfmj IOS9411 604-0
-

TELEFAX IOS9411 604-202

Schutzvecmeck nach e-mail ~jK©neuenhauser .de
D I~" I SO 16016 beachten! E~~-~~orm

Ma Bstab Art. ~jr. OOS93S4 F

Ventilsitz m~ 50, komplett Z. ~~ r . Ve_30160
9s
valve seat m~ 50, complete Index 2 Blatt -~~r. 1
Ersatz fur
Ersetzt durch
VE_30160-0-2 I
 1 2 3 4 5 6 7 8

A ¢280 A

¢250

r420\ (160\
~1~,
~ (60\
/ ~ ~ / /
~
V&__ L -- ~
~

)~,
~ _.-:_ ---1
B <--- B
~
\
"' r==
~
~
r==
~
f--=::
-::.--- /

(20\ 1:5
...........
c:
QJ
D...
0
r400\
1
[
C)
co
.._..--
""
+-
QJ
160 1 S[hei be f iir Skt. S[hraube Form B
washe r
St 140HV 0 IN 125 - B 17 galZn 0064157 [
c:
4--
4--
150 3 Skt-S [hraube 8.8 M 10 X 50 galZn 0050939
•O
QJ
(90\ 140 3
hexag on bolt
Feder ring, aufgebogen A FSt A 10 galZn 0067824
~
01
1 sprin g washer
k\\\\~ ~\\\\\~ 130 1 0 ichtr ing Form A
gaske t ring
Cu A 126x139x2 0054544
§ §~
120 1 Se[hS kantmutter 8 M 16 galZn 0052024
~
~ ~ (80\ hexag on nut
::- Stopfflans[h ON 80
sw 115 r--
:::::
::::::
_=::::
~
-
\J_)
100 1
tampi ng flange 0N 80
9S20K 0059662

? _=:::: 90 1 Stapfbu[hse ON 80 9S20K 0059659

pa[ki ng sleeve 0N 80
~
~
_=:::: '---

~ ~-
ll:l;i fiO\ 80 1 Pa[ku ngss[hnur PTFE 6x6
gland seal
PTFE 0055340

D
~
D t:I:c ..-r-r-
70 1 Grund ring ON 80 9S20K oo59661
base ring
60 1 Stahl ble[h-Handrad d=250 Stahl 0054530
Handw heel • 250
-
50 1 Gewin dest ift m Kegelk+ I nnenskt M8x20 45H M 8 X 20 0080012
M125x4 hexag on so[ket set S[rew M8x20
<--- 40 1 Ventil kegel ON 80 X35CrMo17 0059449
- 130 valve [One ON 80
30 16 Kugel d=5 X40Cr13 0054529
~ ball

I~
20 1 Ventil spindel ON 80 X39( rMo17 -1 0059448

E
""" """
10

Pas.
1
valve spindle ON 80
Spind elf iihrung 0 N 80 St 52-3 n. Z[hg. Ve_20033-b-OO 0059667
valve ~s~pi~nd=le~gu=i~de~DN~8~0--------------------~----------~---------------------+----~
Stk. Benen nung Werkstoff Abmessung/Bemerkung Art. Nr.
E
pas. pie[e des[ri ption material dimension/remark art. no.

0 T .Wegner
) ~IIIII~
10 l% !50\ Index Anderun g Name

~ ~ PC Datum Name Werkstoff-Daten Bez.:

~\46\
Gez. 26.08.2014 T.Wegner Nr.: Bez. (0 IN EN):
Gepr. 27.08.2014

Status Fr
30 Schutzvermerk

F
40 ~ DIN ISO 16016 be

~ Ma Bstab
Vent ile insatz DN 80, komplett z. Nr. Ve_30116
3:5
valve insert ON 80, complete Index 0 Blatt -Nr .: von
Ersatz fur:
Ersetzt dur[h:
VE_30116-0-0 2 3 4 5 6 7 8 A3
 1 2 3 4

I. ¢s~ - D

40 ISicherungsring f Bohrung
11 IFSt 1472 1120 X 4 10243785
seeger circlip ring 120.0 x 4.0
30 11 1st iitzr ing DN 80 1st 35 lve_20184 loo59663 I 0.22
thrust ring
20 11 lstuetzring innen Ventilsitz ON 80 IX6CrNiTi18-10I lve_30105 l1oo4o34 I o.o6
internal support ring
10 11 IDichtring fiir Ventilsitz ON 80 IPA lve_30104 l1oo4031 I o .24
sealing ring
Pos ·1 Stk. IBenennung Werkstoff Abnahme I DIN Abmessung/Bemerkung Art. Nr.IGewicht
IE
1

pos. piece description material inspection dimension/remark art. no. weight

EN10204 [Kgl
Tabelle angepasst 10.12.2014 I T. Wegner
0 03.07.2006 I Scheppm.
Index I Anderung Datum IName
PC Werkstoff -0 aten Bez .:
Gez. Nr.: Bez. (DIN EN): NEUENHAUSER
Gepr. 1o.12.2014 T.Wegner Halbzeug-0 aten Halbzeug-Nr .: KOMPRESSORENBAU
Status Freigegeben Halbzeug: I D-49828 NEUENHAUS
TELEFON (05941) 604-0
DIN-Norm: TELEFAX (05941) 604-202
~--~Sc~h~ut~zv-e-rm-e~rk--na-c~h--~
oIN ISO 16016 beachtenl EN-Norm: e-mail NKoneuenhauser .de
MaBstab 1 Art. Nr. 005944 7 1 F
Ventilsitz ON 80, komplett z. Nr. Ve_30107
1:1
valve seat DN 80, complete Index 1 Blatt -Nr .: 1 von
Ersatz f iir:
Ersetzt durch:
VE_30107-0-0
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 1/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

Order data:
NK-job-no.:
Purchaser: This is a general risk analysis for NK air-receivers / -equipment.
Purchase order no.: It is not intended for a specific project and can be used for all projects.
Final owner, Yard, Project:

Specification, technical Data:

Type / pressure chambers: Compressed-air receiver (compressed-air reservoir), cylindrical air-receiver with dished ends, several volumes, dimensions, constructions
of fastening / mounting, nominal width and assembly of valve head (with or without)
with one pressure chamber
Nominal capacity: up to 25000 L
Quantity:
Ident, serial-no.:
Year of manufacturing:
Operating pressure: standard: 30 bar or acc. to project requirements
Design pressure: standard: 33 bar or acc. to project requirements
Test pressure: hydrostatic pressure test acc. to applied code / regulation
Process fluid: compressed air, water, nitrogen (by appointment only)
Condition of fluid: gaseous, liquid
Fluid group, art. 9: group 2, not dangerous
Allowable min. / max. tem- standard: 0 / +50 °C or acc. to project requirements
perature TS:
Construction, installation: vertical horizontal
Diameter: up to 3000 mm
Plate thickness: acc. to applied code / regulation
Length / height:
Weight:
Approved drawings: several
Code, regulation: Pressure Equipment Directive 2014/68/EU + AD 2000 – Code and/or acc. to project requirements (e.g. code / regulation of class society)
Category: acc. to code / regulation
Module: acc. to code / regulation
Further data: material: main components made from steels for pressure purposes acc. to EN 10028

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 2/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

* Nummerierung in Anlehnung an
DIN EN ISO 12100
use for not intended operation, incorrect applica- - determination, definition and specification of - qualified and skilled personnel for operation
tion, misuse, misapplication technical data and parameter; assignment of (responsibility of owner / operator)
technical limits - training and instructions of the operator
- prepare an instruction manual with description - prevent manipulation of unauthorized persons
of the safe and correct mode of operation by means of warning signs, information boards,
- clear information on name plates barriers and enclosures
- if required operating labels, information signs
and warning signs The plant must not be operated by unau-
thorized persons!

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 3/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

1 mechanical danger due to - design, dimensioning and calculation of the - specification of complete mode of operation and
34.1 - mechanical failure, insufficient mechanical air-receiver according to the operating pres- possible risks due to special loads during con-
strength
- mass and stability
- shape
- accumulation of energy inside the air-receiver
sure and temperature stresses
- consideration of safety factors and allowances
at calculation
- use materials that are suitable for present
tract negotiations
- safe installation, fixing and foundation of the air-
receiver
- control and monitoring of the plant during opera-
!
The plant must be non-pressurized
- liquids and gases under high pressure or nega- stresses, loads and strains tion, regular inspections regarding damages, before any repair and maintenance
tive pressure - chemical resistance of materials and coatings corrosion and wear works!
- mass, weight of a liquid column against the process fluid and environment - execution and documentation of recurring in-
- chemical reactions, explosion conditions spections of the surveying ordinance
- temperature stress and exposure - analysis of experiences with similar applica- - prevention of incorrect use
- Failure of pressure retaining walls, bursting /
explosion of the tank
tions
- review of the design and documentation by an
rd
approved 3 party inspection organisation
- if applicable: consideration of special events
- safety actions to prevent forbidden loads by
means of suitable safety-, protection-, control-,
and monitoring- devices (i.e. safety valves,
burst-discs, pressure switches, temperature
!
In case of cracks, holes, cavities, rolling
and special loads that can occur in addition to controls, limiter at pressure generator, control at
imperferctions and other defects on
the operational loads (for example seismic steam generator, pressure reducers etc.)
steel plates, housings, and welded
events) - testing of safety devices before start-up the
seams the plant has to be shut-down
- material tests, material certifications, identifi- plant
immediately!
cation and traceability - adequately dimensioned safety valves
- suitable and proven fabrication technologies - pressure indication with marking of the allow-
and processes able pressure
- compliance to manufacturing tolerances - pressure measurement with alarm signals at
- professional preparation of the components excessive pressures
- quality preparation of weldings - temperature measurement and alarms
- approved welding consumables and filler - avoid excessive temperature of the process fluid
metals and excessive heat radiation from surrounding
- approved welding procedures and welding heat sources
qualifications - Piping and further equipment should be installed
- qualification and certification of welding per- strainless. (e.g. w. flexible hoses)
sonnel, approved welding supervisor - use suitable pipe-work, hoses, fittings and
- tests during fabrication, tests of welded joints armatures, safe and proper fixing of the such
- non destructive tests and production test - de-pressurize the plant before any repair and
samples as required maintenance works
- qualifified personnel and subcontractor for
non-destructive testing
- witness inspection, final inspection, construc-
tion test, pressure test
- marking, labelling
- providing an owner instruction manual
- avoiding sharp edges and angles

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 4/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

1 tumescent / alternating / dynamic loads if applicable - complete definition of the operation mode, fore-
alternating pressure fluctuations - design and calculation of the air-receiver cast of the expected load cycles if applicable
appropriate to withstand expected pressure
fluctuations during operation
- geometric design design and welding prepa-
ration to prevent stress peaks, notch effects,
- inform the manufacturer about alternating pres-
sures during contract negotiations
- registration and documentation the number of
load cycles during operation
!
The inspection intervals for recurring
stress concentration and crack fissuration - observance of the inspections when reaching test are to be observed and apply to
- selection of material (soft, ductile steel certain critical numbers of load cycles both the air-receiver and the valve head!
grades) - control for cracks and other damages
- suitable welding preparation, prevent weld- - avoid corrosion
ing imperfections
- surface quality (small roughness)
- consider safety factors and allowances
- design calculations according to AD 2000
regulation S1 resp. S2
!
The air-receiver is to be checked regu-
- definition of allowable pressure fluctuation
larly for cracks and damages!
and load cycles during lifetime
- definition of intervals for recurring inspec-
tions
- specification of the design data on the draw-
ing
- note in the owner’s instruction manual
1 Wear, abrasion, erosion and corrosion - material selection, resistant material or resis- - regular controls for corrosion and wear
ageing, material fatigue tant coating against the contacting fluids - control of wall thicknesses
scaling - internal coating with a corrosion protection
painting
- instructions in the owner’s manual
- if required calculation / design considering a
- inspections for damages, dint, cracks, deforma-
tions und leaks
- consider operating experiences
- maintenance plan, regular maintenance and
!
The air-receiver must be checked regu-
corrosion allowance inspection of the plant larly for corrosion and wear!
- arrangement of drain facilities - protect the coating against mechanical dam-
- arrangements for cleaning and openings for ages
inspection - observe the prescribed intervals for recurring
inspections, internal inspection and pressure
test, documentation and archiving in a air-
receiver book
- consider shortened inspection intervals in case
!
The inspection intervals for recurring
of awkward loads
- protect the equipment against dust and dirt test are to be observed and apply to
- remove contaminations and solid (abrasive) both the air-receiver and the valve head!
particles from the fluid by means of suitable
filters, meshes and separators
- regular drain of condensate
- regular cleaning of the air-receiver

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 5/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

1 Opening under pressure - note in the owner’s manual - warning notes for the operating personnel
- arrangement of drain and ventilation devices - training, qualification, instruction and briefing of
the operator
- labelling and warning plates !
The air-receiver must not be opened
under pressure at any circumstances!

1.9 Dangers because of penetration or squirting of - use suitable flange connections, pipe-fittings,
liquids or gas at high pressure or high tempera- sealings, gaskets considering fluid, pressure
ture and temperature
- install pipes and hoses centered and strainless,
do not cant pipes and armatures
- use suitable bolts and fittings
!
The plant must be non-pressurized
- check for proper sealing faces and threads before any repair and maintenance
- use suitable armatures for pressure and tem- works!
perature
- care for safe discharge of fluid when persons
can stay in the danger zone , for example at
safety valve blow-off
- shut-down the plant and depressurize the air-
receiver before any works on the air-receiver
and before opening the air-receiver
- use safety equipment, protective clothing, safety
goggles
- arrange protector guards, barriers and enclo-
sures
2 electrical risks, electrical voltage - not applicable
3 thermical risks and hazards caused by very high / - installation of the air-receiver in way that there is
3.1 or very low temperatures, flames, explosion and no impact to any person
3.2 heat radiation - safety area surrounding the air-receiver to
prevent contact to hot or cyrogenic surfaces
(fences, protection plates, insulations
- use personal safety equipment, gloves, etc.
- warning signs
Supposedly hot surfaces, direct contact
should be avoided and protective gear
should be worn!

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 6/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

4 Risks, health damages due to noise, impact - note in the operating instructions - mount a silencer
4.1 acoustic shock at compressed-air discharge at - wear ear protection
4.2 release of pressure - appropriate distance between safety valves and
working places and persons
- discharge pipe at safety valve blow-off

Looking directly into the compressed air

openings must be avoided!

5 Risks because of vibration - not applicable

6 Risks because of radiation - not applicable
7 Dangers due to material, additives and other - note in the operating instructions - operation exclusively with the intended process
7.1 chemical substances fluid
7.2 Contact or breathing of dangerous liquids, gases, - ventilation of the work place, extraction of harm-
7.3 mist, vapour, steam or dust ful gases, vapours and solvents
21.2 biological or microbiological hazards - prevent filling with dangerous, aggressive, toxic,
21.3 exhausts, anoxia at work place inflammable, explosive or acidly substances
21. - prevent accidentally discharge of the process
10 fire and explosion, external fire fluid (refer to 1.9)
32
33
- if required use personal safety equipment,
breathing protection, etc
- arrange safety provisions
- install fire protection (sprinkler,alarms)
!
The pressure receiver must not be oper-
- install fire extinguisher ated with dangerous, aggressive, acidly,
- emergency exits, evacuation routes toxic, corrosive, abrasive, inflammable
or explosive substances!

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 7/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant
ATEX Directive
Remark concerning Directive 94/9/EC (ATEX
directive):
An analysis regarding the installation of such air
receivers in potential explosive areas was
carried out.
The result / conclusion was:
The air receiver / valve head is not within the
scope of that directive. Therefore a classifica-
tion / certification according to ATEX is not
possible.
The air receiver can be operated in EX- - if required install devices against electrostatic
classified zones without any restrictions. charges (earthing of the air-receiver)
The only possible source of ignition is electro-
static charging.
7. Leakages, accidentally release of dangerous - note in the operating instructions - use suitable sealings abd flange connections
7.1 substances - install arrangements to drain leaking fluid safely
7.2 - if required arrange EX-classified areas and
7.3 install EX-classified equipment
21.2 - install gas detectors
- keep safety clearance
8 risks because of disregarding ergonomic princi- - convenient ergonomic design of the plant - clarity, illumination of the work place, of operat-
8.1 ples ing elements, displays and signals
8.3 awkward operation - placing and handling
8.4 unhealthy work position (bearing) - accessibility and enough space for service and
8.6 overstraining the personnel maintenance of the equipment
8.7 slipping, stumbling or falling of persons - protective clothing
8.8 - safety equipments
10.6 - clear instructions, simple handling and opera-
1921. tions
1 - fences, guardrails
21.2 - optical and acoustic warning signals
21.5 - keep traffic routes, escape ways and emer-
21.6 gency exits clear
21.82 - maintain safety distances
1.9
25.3
29
29.1
31

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 8/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

9 combination of risks - the plant / system must be engineered and

protected in a way that the combination of some
(minor) risks can not cause dangerous situa-
tions.
10.1 Breakdown / failure of control and supervising - note in the operating instructions - the plant has to be engineered so that failures
10.2 systems can not cause dangerous situations
13
14
Breakdown and reconstitution of energy (power)
supply
Failure of safety systems
- if required installation of redundant systems
- installation of safety valves, bursting discs,
fusible plugs
- prevent blockage, contamination, dirt, freezing
!
Freezing, sticking or blockage of the
Freezing of the plant, blockage or destruction of or sticking of the safety valve safety valve must be avoided!
air-receiver, piping or armatures because of - devices to prevent freezing
freezing condensate - drain the plant if risk of freezing
- install freezing protectors, heaters in critical
areas
10.4 other external loads (wind, earthquakes,…) - design according to applicable external loads, - analysis and specification of additional loads.
additional forces, pipe reaction-forces, earth- - information of the manucturer
quakes, wind,… - safely installation and foundation
- provide reinforcements - provisions to reduce and withstand such influ-
- refer to No. 1 ences (reinforcements, supports, compensator,
bearings)
11 lack the possibility to shut-down the plant within - The air-receiver must be integrated into the
optimal conditions system in a way that a safe shut-down is possi-
ble without any problems always.

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 9/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

15 bad installation, bad setup - adequate instructions in the owner’s manual - safe installation, fastening and foundation
18 tilting, insufficient stability and on drawings - consider filling weights at setup and foundation
27.1 risks at transport, setup and commissioning - arrangement of fastening devices, - use of suitable and safe transport and loading
27.6 loads falling down - feet, saddles, brackets, lifting lugs equipment
- suitable transport protection and packing - suitable lifting devices, chains and ropes, usage
of trusses
- lifting up the ai-receivers only when empty, i.e.
without filling of compressed-air / water
No persons are allowed to stay in the
- consider the centre of gravity, use the provided
danger zone!
lifting lugs
- ensure proper commissioning, piping, connec-
tion and operation
- assemble the valves, pipe-work und hoses
unpressurized and strainless
- adhere to the specified fastening torques
- use only suitable and correct armatures, piping,
sealings and fittings
- ensure qualified and trained operating person-
nel
- arrange the authorities acceptance of the plant
before putting into operation (inspection of in-
stallation)
25.1 unauthorized start-up / operation - protect the plant against unauthorized start-up
and operation
- warning signs

The plant has to be protected against

illegal start-up and manipulation!

26 insufficient instructions of the operating personnel - providing operating instructions - training, briefing and qualification of the operat-
- labels and warning signs attached to the ing personnel
equipment if required - warning signs and labels at the plant

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 10/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

27.1 mechanical dangers and risk events due to falling - design and reinforcement of the air-receiver - protection devices (safety areas, fences, barri-
27.4 loads, collisions to the machine for sufficient stability ers)
mechanical impacts from other surroundings - avoid vibrations at the installation place (vibra-
tion damper)
- avoid unacceptable loads caused by reaction
forces from supports and pipes (installed
strainless)
- reinforcements and bracings on supports and No persons are allowed to stay in the
piping, compensators danger zone!

37 human erratic behaviour, human behaviour - providing operating instructions - Training, briefing and qualification of the operat-
- if required labels and warning signs on the ing personnel
de-activating or avoiding of safety- and protection equipment - warning signs and labels at the plant
devices - install security systems
- automatic control- and monitoring systems
- redundant safety systems
- prevent manipulation by unauthorized persons
with means of fences, warning signs and appro- Access of unauthorized persons and
priate instructions manipulation at the plant is strictly for-
bidden!

others - formed and forged components are purchased - the final owner has to specify and check the
at spezialized sub-suppliers. The relevant requirements and risks in case that the air-
standards, rules and tests are specified in the receiver is installed in special plants (e.g. nu-
order. clear plants, big chemical industries, ships, off-
- A heat treatment on the air-receiver is not shore drilling platforms etc)
required. The flanged ends are hot-formed or - general accident prevention measures, safety
heat treated at the supplier according to AD regulations, and other rules and standards are
HP 7/2, HP 8/1 regulations. to be observed
- it is not allowed to carry out welding works, heat
treatments or any other structure modifications
on the air-receiver without the approval of the
surveying authority

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Designation: Neuenhauser Kompresso-
renbau GmbH
Analysis of dangers and risks Hans-Voshaar-Straße 5
D- 49828 Neuenhaus
for pressure equipment / accessories acc. to PED 2014/68/EU
Page: 11/11
No.* Risk / Danger event Safety action, examples
refer to: DIN EN ISO 12100 Actions at manufacturer side Actions at operator / owner side Warning note,
AD 2000-Leaflet Z2 Design, dimensioning and fabrication of the Actions at operation, installation, commissioning, remaining risk
PED 2014/68/EU pressure equipment / accessories equipment of the plant

Remarks:
The plant or system contractor respectively This analysis of dangers and risks is a
The installation of the complete plant with The final owner has to check which risks
the final owner is responsible for the correct general list of possible risks / dangers
maybe further required safety valves and have to be considered in regarding to
installation, set-up, commissioning, initial when operating a compressed-air re-
other safety-, control-, and monitoring operation of the air-receiver at his plant.
inspection, recurring inspections and safe devices is done by the owner. ceiver / pressure equipment. This analy-
The safety action proposals are to be
operation mode. sis will be amended by the correspond-
The design of the air-receiver will be ap- understood just as examples.
ing operating instructions.
Standard air-receivers are usually sup- proved by an independent notified body
The final owner must decide which
plied with a valve head manifold. (e.g. TÜV) according to the operational Additional risks that we as manufacturer
safety actions are applicable and which
A safety valve is installed at the valve parameter that are specified on the draw- don’t know may exist; depending on the
are required.
block. ing (design review). installation place, operation mode, plant
Further a pressure indication device can periphery and environment. Furthermore, the operator is responsible
be supplied on request. for the attachment of all necessary warn-
Otherwise some of the listed risks dan-
The necessary information, instructions ing / safety signs and instructions!
gers might not occur at the concrete
and descriptions are included in the
application of this project.
operating instructions.

Project document submitted

for information only

for discussion
For review / approval STATUS:
accepted for construction accepted with comments not accepted

“as build”

Neuenhauser Kompressorenbau GmbH,

Neuenhaus, 19.07.2016

(NK-employee)

Client, place, date

Prepared by: WT / Bhs Date: 19.07.2016

© Neuenhauser Kompressorenbau GmbH - Subject can be changed - Revision status: 02
 Benennung/Designation:

Rev: 006
Schmierölempfehlung / Lubrication chart
Page: 1/1

Empfohlender Lieferant/ Bezeichnung / Designation Bemerkungen

Recommended Supplier DIN 51506 / VDL 150 Remarks

Aral Motanol HE 150 Mineralöl / mineral oil

BP Energol RC 150 Mineralöl / mineral oil

Agip DICREA 150 Mineralöl / mineral oil

RENOLIN 505 VDL 150 Mineralöl / mineral oil

RENOLIN UNISYN OL 150 Synthetiköl / synthetic oil

Mobil RARUS 429 Mineralöl / mineral oil

Mobil RARUS 829 Synthetiköl / synthetic oil

Shell Corena S2 P 150 Mineralöl / mineral oil

TOTAL DACNIS 150 Mineralöl / mineral oil

Datum/Date: 10.09.2013 08:40:00

Technische Änderungen vorbehalten / Subject to be changed
 ------,

Neuenhauser Kompressorenbau GmbH

Hans-Voshaar-Str.5
D- 49828 Neuenhaus
Mai!: [email protected]
Tel: 0049 (0) 5941 6040

Erklärung zur Verordnung EG Nr. 1907/2006 zur Registrierung, Bewertung, Zulassung

und Beschränkung chemischer Stoffe (REACH)

Aus der REACH Verordnung gehen für uns keine Pflichten aufgrund der Herstellung und des
Inverkehrbringen von Substanzen/ Chemikalien zur Vor-Registrierung bzw. Registrierung
hervor.

Die von uns verwendeten Produkte wurden auf ihre Inhaltsstoffe überprüft. Bis dato hat
Neuenhauser Kompressorenbau GmbH keinerlei Hinweise von seinen Lieferanten erhalten,
dass gegebenenfalls registrierungspflichtige Inhaltsstoffe in unseren Erzeugnissen enthalten
sind.

Aus diesem Grunde ist bis auf Widerruf der oben genannten Angaben davon auszugehen,
dass alle derzeit eingesetzten Inhaltsstoffe weiterhin verfügbar sein werden und somit kein
an unsere Kunden geliefertes Produkt gefährdet ist.

Regulation EC 1907/2006 concerning the Registration, Evaluation, Authorization and

Restriction of Chemicals (REACH)

Based on the REACH regulation there are no responsibilities arising from the manufacture
and marketing of substances / chemicals for pre-registration or registration for uso

The products we use have been tested for their constituents. Until now Neuenhauser
Kompressorenbau GmbH has received no evidence from its suppliers that our product
contains ingredients requires registration.

Due to that reason (untiI further notice) of the above mentioned it can be assumed that all at
present used ingredients will be available further on and therefore no delivered product to
customers is endangered.

Neuenhaus, den 31.10.2011

~ c-e.-s<--
Möller
Leiter OS 10MB
Hazardous Material Verified Declaration
This form is based on IMO MEPC.269 (68) Draft Guidelines dated August 2015

< Supplier Information>

Neuenhauser
Company Name
Kompressorenbau GmbH
Division Name Pressure Equipment
Hans-Voshaar-Str. 5
Address
D-49828 Neuenhaus
Contact Person Tim Wegner
Telephone No. +49 5941 604-0
Fax No. +49 5941 604-202
E-mail Address [email protected]

<Product
- ----- - Information>
-
Product Total Mass
. Product Name Product Number Product Information
Mass Unit
all products of a.m .
division (company)

<Material Information>
Internationally If yes,
tf, yes, Material
added above detailed
Table Material Name Threshold Level Mass
threshold level Material
Yes I No Mass Unit tnfonnation

Asbestos Asbestos 0,1% No

!
Polychlorinated
Biphenyls Polychlorinated Biphenyls 50 mgl kg No
(PCBs)
CFCs No

Halons No
Other fully halogenated
No
CFCs
Table A
(Materials Carbon Tetrachloride No
listed in Ozone Depleting 1,1,1- Tri chloroethane No threshold
Appendix 1 of Substance level No
(Methyl Chloroform)
th e
Convention) Hydrochlorofluorocarbons No

Hydrobromofluorocarb ons No

Methyl bromide No

Bromochloromethane No

Tributyl Tin s No
Organotin
Triphenyl Tin s 2500 mgl kg No
compounds
Tributyl Tin Oxide (TBTO) No

Internationally
If, yes, Material lfyes, I
added above detailed
Table Material Name Threshold Level Mass
threshold level Material
Yes I No Mass Unit lnfonnation ,

Cadmium and Cadmium Compounds 100 mglkg No

Hexavalent Chromium and Hexavalent
1000 mgl kg No
Chromium Compounds
Lead and Lead Compounds 1000 mgl kg No
Table B
Mercury and Mercury Compound 1000 mgl kg No
(Materials
Li sted in Polybrominated Biphenyl (PBBs) 50 mgl kg No
Appendix 2 of
the Polybrominated Dephenyl ethers (PDBEs) 1000 mgl kg No
Convention)
Polychloronaphthalanes (C1=>3) 50 mgl kg No
No threshold
Radioa ctive Substances No
level
Certain Shortchain Chlorinated Paraffins 1% No

The object of declaration described above is in

conformity with the Guidelines for the
development of Inventory of Hazardous te~S~ert\
W~uGmbH
· · ····· · ··· ~·
~... n'4h.;tll!.,._ ,
Materials IMO MEPC.269 (68).

Notice: Any significant change in material content may render thi s declaration invalid! Any c h anges or amendments by others than
the author (a .m. company) of this form constitute a breach of copyright law!
 1 I 2 3 I 4

Sicherheitsventil-bauteilgeprUft Safety-valve type-approved

Bauteilwerkstoff: Messing body-material: brass A
Typ 2108 <vorher 2122> Type 2108 <previously 2122>
Anschlullgewinde: G 112 Connection: G 1/2
Nennweite: DN 8 Nominal-diameter: DN 8
-
Dichtwerkstoff: FKM Sealing material: FKM
Anwendungstemperatur: -20°( bis +200°( Operating temperature: -20°( to +200°(
frei abblasend open discharge

B
Einstelldruck ca. Abblaseleistung <Luft> Artikel Nr.
I I
adj. pressure approx. blow-off capacity<air> article no.
7 bar 226 Nm"3/h 0077093
'
8 bar 255 Nm"3/h 0055350 -
10 bar 313 Nm"3/h 0061983 I
11 bar
12 bar
342 Nm"3/h
371 Nm"3/h
0265280
0215050
I
16 bar 485 Nm"3/h AC-valve I 0
18 bar 543 Nm"3/h 0081449
I 0\ c
30 bar 889 Nm"3/h 0055390
0
31 bar 915 Nm"3/h 0055348 i u
32 bar 942 Nm"3/h 0070886 sw 27
33 bar 971 Nm"3/h 0055347 .......... !'- I
34 bar 1000 Nm"3/h 0221805 i -
35 bar
38 bar
40 bar
1029 Nm"3/h
1115 Nm"3/h
1177 Nm"3/h
0222444
0234195
0055392
0 cp a
41 bar 1203 Nm"3/h 0313811 N
42 bar
43 bar
1229 Nm"3/h
1258 Nm"3/h
0055388
0435179
I
I
......-
D
44 bar 1287 Nm"3/h 0113937 G1/2
45 bar 1316 Nm"3/h 0118278
026.1
-

E
i Zeichnung aktualisiert 26.03.12 J. Boll j Tabelle aktualisiert 29.05.12 J. Boll
And-Nr Anderung Datum Name And-Nr Anderung Datum Name

Gez.
Datum Name Werkstoff-Daten
14.11.96 SChepp Nr: 2.0380
Gepr. 29.05.12 Boll/Bhe Halbzeug
Status F reigegeben
DIN
Bez. (altl:
Bez. <DIN ENl:
CuZn39Pb2
CuZn39Pb2
Abmessung
N( NEUENHAUSER
KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON 1059411 604-0
-

Schutzvermerk nach NHS TELEFAX <059411 604-202

eMail NKIIneuenhauser.de
ISO 16016 beachten! PC 46 Internet www.neuenhauser.de
Allgemein- Manstab Artikel-Nr. F
toleranzen Sicherheitsventil ON 8 Z. Nr. Ve_20654
ISO 2768-mK 1:1 Index j Blatt-Nr. 00 von: 00
Safety-valve ON 8 Ersatz fUr:
Ersetzt durch:
A4
 D- NL- F-EN ~
HEROSE GROUP
r

Bedienungsanleitung Instructions de service

Sicherheitsventile Typen 2024/2032/2048/2108/2110/2115/2120/2125/2132 Soupapes de securite des types 2024/2032/2048/2108/2110/2115/2120/2125/2132
ANWENOUNGSBEREICH SICHERHEITSVENTIL (SV) DO MAINE D'AP:LICATION DE LA SDUPAPE DESECURITE
Ausschlie31ich zum Absichem von Oberdriicken in Behallem und Rohrleitungen. Unzuliissig: Einsalz als Ober- Exclusivement pour Ia protection contre les surpressions dans les recipients et les conduites. Non admissible : une
strBmeinrichtung, Regelventil oder Ablassventil im Dauerbetrieb. Permanentes Abblasen beschadigt das SV. utilisation en tant que dispositif de lrop-plein, soupape de reglage ou soupape de decharge en service continu. Une
Zuliissige Medien - Druckluft bzw. ungiftige, neutrale und nicht brennbare Diimpfe und Gase, die frei austreten decharge permanenle endommage Ia soupape de securite. Produits autorises- Air com prime, vapeurs et gaz non
durfen. Zuliissiger Temperaiurbereich- 20' Cbis + 200'C (Viton) /- 50' Cbis + 150' C(EPDM). Bei der loxiques, neutres et non inflammables pouvant s'echapper librement. Pfage de temperature admissible:
Verwendung von ungeeigneten Medien (brennbar, giftig usw.) beslehen Gefahren fUr Anwender und Umwelt. Das -20"C a + 200'C (Vilon) /-50' Ca + 150"C(EPDM). ~utilisation de produits inadequats (inflammables, toxiques,
SV kann zerstort werden. Lagerung - SV nur in sauberer und trockener Umgebung lagem! Schmulz, aggressive- etc.) entraine des dangers pour l'utilisateur et l'environnement. La soupape de securite peut etre irremediablement
und feuchtigkeitsbelastete Lagerorte kfinnen das SV beschiidigen. Einbaulage des Ventiles muss so erfolgen, dass endommagee. Stockage - Ne stocker Ia soupape de securite qu'en environnement sec et propre ! Les lieux de
das Umfeld die Funktion des Ventiles nicht beeintriichtigen dart, z. B. Schulz gegen mfigliches Eindringen von stockage encrasses, hum ides ou conlenant des substances agressives peuvent endommager Ia soupape de
Wasser, Schmulz, Schnee, Feuchtigkeit. securite. La position de montage de Ia soupape doil etre lelle que l'environnement ne gene pas le fonctionnement
MONTAGEIEINBAU de Ia soupape, p. ex. protection contre Ia penetration d'eau, d'impuretes, de neige, d'humidite.
Personal: Einbau nur von qualifiziertem Fachpersonal! Einbau - Geeignetes Gegengewinde und nulzbare Gewin- ASSEMBLAGE/MONTAGE
deliingen vorbereiten. Dichtrnaterial - Entsprechend der erwartelen Temperaturen/Belastungen auswiihlen'. Personnel : Montage unique men! par un personnel specialise qualifie ! Montage- Preparer un contre-filet ada pte
Einbaulage: SV senkrecht nach oben einbauen. Fremdkorper konnen dadurch nach unten in den Behaller oder in et des longueurs de filet adequates. Materiau d'etancheite - Aselectionner en fonclion des temperatures et des
die Hauptrohrleitung zunickfallen. Montage- Feslziehen der Gewinde nur mil passendem Gabel- oderVerstell- contrainles probables. Positionnement- Monter Ia soupape a Ia verticale orientee vers le haul. Les corps
etrangers peuvent ainsi retomber dans le recipient ou dans Ia conduite principale. Assemblage- Serrage des filets
schliissel mit glatten Backen. Werkzeug nur am 6-Kant des Ventilunterteiles anselzen. Ungeeignetes Werkzeug
uniquement avec une cle a fourche ou une cle de reglage a mors lisses. Appliquer l'outil seulement sur l'hexagone
kann das Ventilunterteil deformieren und zur Funktionsunfiihigkeit fiihren. Notwendige Anzugsmomente
de Ia partie interieure de Ia soupape. Un oulil inadapte peut detormer Ia partie inferieure de Ia soupape et porter
eigenverantwortlich festlegen. Sauberkeit- Es diirfen keine Resle von Dichtrnitteln am und im Venti! sein.
prejudice au fonctionnement. Les couples de serrage requis sont fixes de maniere autonome. Proprete - Aucun
Zuleitung und Einbau sons!. Annaturen- Der Einbau eines Schmulzfiingers/einer Absperrarmalur in die
residu de materiau d'elancheile ne doit se trouver sur ni dans Ia soupape. Conduite d'alimentation et montage
Zuleitung is! nach den Regeln unzuliissig.Auf ausreichenden Leitungsquerschnitt achten! Witterungsschutz-
d'autres accessoires de tuyauterie- Le montage d'un collecteur d'impurelesld'un dispositif de fermeture dans Ia
Geeignete MaBnahmen zum Schulz gegen Schnee, Eis, und Festsloffpartikel sind zu treffen. Geeignet sind conduile d'alimenlation n'est pas admissible seton les regles de Ia technique. Veiller a une section de conduite
Oberdachungen, die den Ausfluss nicht behindem. Einbauort- Derart wiihlen, dass beim Ansprechen des SV suffisante ! Protection contre les intemperies - Prendre les me-sures requises de protection contre Ia neige, Ia
infolge der oft sehr gro3en Ausflussmengen keine Personen zu Schaden kommen oder Schiiden an Einrichtungen glace et les particules solides. Conviennent par exemple des auvents ne portant pas prejudice a l'ecourement. Lieu
entstehen. Das SV fiirWartungsarbeilen zugiinglich machen und nicht in Verkehrsriiume ragen lassen. de montage - Choisir le lieu de maniere ace que le de-clenchement de Ia soupape, souvent accompagne de tres
lnbetriebnahme- Bei der ersten lnbetriebnahme das SV anliiften! Urn evtl. vorhandene Partikel auszublasen. Siehe grandes quanlites d'ecoulement, ne porte pas prejudice aux personnes ni ne provoque de degats materiels sur les
"Anliiftvorgang ". Wamung- Beim Anliiften achten Sie bitte auf lhr Umfeld, dass keine Personen oder Sachen durch installations. Prevoir une accessibilite de Ia soupape pour les travaux de maintenance et ne pas Ia laisser saillir
das austrelende Medium zu Schaden kommen. · · dans des espaces de circulation. Mise en service- Purger Ia soupape de securile de son air a Ia premiere mise en
BETRIEB/ANWENOUNG service ' Ceci afin de la'degager d'evenluelles particules en presence. Voir • procede de purge •. Avertissement-
Elnsalz- Das SV nur fUr seinen Einsatzzweck verwenden. Der Betriebsdruck soli hiichstens 15% unler dem Tenez compte de votre environnement au moment de Ia purge afin que le produit ejecte ne provoque aucun
Einstelldruck liegen. Wartung - Wartungsintervalle sind einzuhallen. dommage aux personnes au aux biens.
WARTUNG UND INSPEKTION SERVICE/UTILISATION
Achtung Verbrennungsgefahr- SV und Medium konnen betriebsbedingt heiB werden - Kfirperschulz tragen Mise en muvre- La soupape de securite ne doit etre utilisee que pour les fins prevues. La pression de service ne doit
(Handschuhe, Schulzbrille). Wartungsintervatl - Wartung muss durchgefiihrt werden, lntervalle liegen im pas etre inferieure de plus de 15 % a Ia pression de reglage. Maintenance - Respecter les intervalles de maintenance.
Ermessen des Anwenders. Sichtpriitung- Das SV ist auf Verschmulzungen und mechanische Beschiidigungen zu MAINTENANCE ET INSPECTION
pniten. Anliiften- Urn testsilzende Schmulzpartikel zu losen ist das SV event. mit Druckunterstiilzung anzuliiften. Attention- Risque de bnilure- La soupape de securite et le produit peuvent etre Ires chauds en service normal -
Dabei Schulzbrille, Gehorschulz und Handschuhe lragen. Das ausslrfimende Medium kann Schmulzpartikel Porter une protection corporelle (gants, lunettes de protection). lntervalle de maintenance- Une maintenance est
mitschleudem, Liirm- und Temperaturbelastung entsteht. Anliiftvorgang :Anlage unler Druck stellen, mind. necessaire, les inlervalles de maintenance sont a Ia discretion de l'utilisateur. Controle visuel - Conlrfiler !'absence
80-90% derVentileinslellung. Die Anliiftschraube einige Umdrehungen nach links drehen, bis das SV abblasl, d'encrassement el de deteriorations mecaniques sur Ia soupape de securite. Purge d'air - Pour detacher les
danach bis Anschlag nach rechts zunick, das Venti! ist wieder dicht. Reinigung - mit trockenem Tuch. Beim particules d'impuretes lenaces, Ia soupape doit eire purgee manuellement, le cas echeant a !'aide d'air comprime.
Reinigen der Gesamtanlage SV abdecken. Aggressive Medien konnen die Funktion beeintrachtigen. Porter a cet effet des lunettes de proJection, une protection auditive et des gants. Le produil ejecle peut contenir
REPARATUR/GARANTIE des particules d'impureles, il y a formation de bruit et de chaleur. ProcOde de purge - Mettre !'installation sous
Achtung! Jegliche Demontage des SV ist verboten. Mit Lfisen der Plombe erlischt die Herstellergarantie und pression, avec au moins 80-90 % du reglage de Ia soupape. Toumer Ia vis de purge de quelques rotations sur Ia
Zulassung. Mechanische Veriinderungen - Offnen des Venlils od. Anderung des Einslelldrucks nur durch Herstel- gauche jusqu'a ce que Ia soupape commence a decharger, toumer ensuite a droite jusqu'a Ia butee, et Ia soupape
ler oder aulorisierte lnstitutionen. Diese Einbau- und Betriebsanweisung sollte dem Pnifungs-Sachversliindigen, est a nouveau etanche. Nettoyage -avec un chiffon sec. Lorn du nettoyage, recouvrir toutle dispositif de soupape.
z.B. TOv oder DEKRA bei der Abnahme vorgelegt werden. Les produits agressifs peuvent porter prejudice a son fonctionnemenl.
REPARATION/ GARANTIE
Kelinzeichnung siehe Vorderseite Attention I Tout demontage de Ia soupape de securile est interdit. Le detachement du plomb entraine !'expiration
c[e Ia garantie du fabricant de meme que de l'homologalion. Modifications mecanlques- Ouverture de Ia
soupape ou modification de Ia pression de reglage uniquement par le fabricant ou des organismes autorises.
Gebruiksaanwijzing Les presenles instructions de montage et de service doivent etre presentees au moment de Ia reception a !'expert
Veiligheidskleppen type 2024/2032/2048/2108/2110/2115/2120/2125/2132 mandate par l'organisme de controle technique, p. ex. TOv ou DEKRA
Marquage voir au recto
TOEPASSINGSGEBIED VEILIGHEIDSKLEP
Uitslilitend voor het beveiligen van overdrukken in reservoirs en pijleidingen. Niet toegestaan: gebruik als
overstroominrichting, regelklep of aftapklep in continugebruik. Permanent afblazen beschadigt de klep.
Toegestane Media - Perslucht of niet-giftige, neutrale en niet brandbare dampen en gassen die vrij mogen Operating Instructions
uitstromen. Toegestaan temperatuurbereik: -20'C tot +200'C (Viton) /-50'C tot+ 150' C(EPDM). Bij het gebruik Safety Valve, Type 2024/2032/2048/2108/2110/2115/2120/2125/2132
van ongeschikte media (brandbaar, giftig enz.) bestaan gevaren voor gebruiker en milieu. De veiligheidsklep kan
worden vemietigd. Opslag - Veiligheidskleppen mogen aileen in een schone en droge omgeving worden AREA OF APPLICATION SAFETY VALVE (SV)
opgeslagen! Opslagplekken die zijn belast met vuil, agressieve Iucht en vocht kunnen de klep beschadigen. Exdusively for use in protecting against overpressures in containers and pipes. Not permitted for use as a differential
lnbouwposilie van de klep moet zodanig zijn dat de omgeving de werking van de klep niet kan belemmeren, bijv. pressure release device, regulation valve, or release valve for continuous use. Permanent releasig damages the SV.
bescherming tegen mogelijk binnendringen van water, vuil, sneeuw, vocht. Pennitted Media- Compressed air and/or non-toxic, neutral, and non-flammable vapours and gases which can be
MONTAGEIINBOUW allowed to escape into the atmosphere. Pennitted temperature range: -20' Cto +200" C(Viton); -50' Cto+ 150' C
Personae! - De inbouw mag aileen worden uitgevoerd door gekwalificeerd geschoold personae!! lnbouw - (EPDM). The use of unsuitable media (flammable, toxic, elc.) is hazardous for the user and the environment This can
Geschikte legendraad en bruikbare draadlengtes moelen worden voorbereid. Afdichtingsmateriaal - Dit moet also irreparably damage the SV. Storage- The SV is to be stored only in dean,' dry environments! Contaminated
voor dele verwachten temperaluren/belastingen worden gekozen. lnbouwpositie - De veiligheidsklep moet environments, as well as environments containing aggressive agents or high moisture levels can damage the SV. The
verticaal naar boven gericht worden ingebouwd. Vreemde voorwerpen kunnen daardoor naar beneden in het valve must be installed so as to ensure that nothing in the immediate vicinity of the valve disturbs its operation; thus, it
reservoir of in de hoofdpijpleiding lerugvallen. Montage - De schroefdraad moet met een passende steeksleulel of must be protected against the penetration of water, contamination, snow, and moisture.
verstelsleutel met gladde bekken worden vaslgedraaid. He! gereedschap moe! worden aileen aangezet op de MOUNTING/INSTALLATION
6-kant van hel kleponderstuk. Ongeschikt gereedschap kan het klepondersluk vervormen en dit kan ertoe leiden Personnel- The device may be installed only by qualified personnel' Installation- Prepare the suitable mating
dat de klep niet meer tunctioneert. Toegestane aanhaalmomenten moeten absoluut worden aangehouden. threads and the appropriate thread lengths. Sealing material- Select the sealing material to correspond lo the
Noodzakelijke aanhaalmomenten op eigen verantwoordelijkheid vastleggen. Zuiverheld - Er niogen zich geen expected temperatures and other influencing factors. Mounting orientation- Mount the SV vertically and in an
resten van afdichtingsmiddelen open in de klep bevinden. Toevoerleiding en lnbouw van overige koppelstuk- upright orientation. Foreign bodies can thus fall back into the container or main pipe. Mounting- Use only a
ken - De inbouw van een vuilvanger/afsluitkraan in de loevoerleiding is volgens de voorschriften niet toegestaan. suitable fork wrench or adjustable wrench with smooth jaws to tighten the threaded connection. Apply the tool only
Er moet op worden gelet dat de leidingdoorsnede groot genoeg is! Beschennlng tegen weersinvloeden - Er to the hexagonal edge of the bottom of the valve. The use of unsuitable tools can deform the botlom of the valve
moeten geschikte maatregelen ler bescherming tegen sneeuw, ijs en vaste slofdeelljes worden getroffen. Geschikt and result in a loss of function. Determine the necessary tightening torque yoursell. Cleanliness- No residual
zijn overkappingen die de uitstroming niet belemmeren.lnbouwplaats- Kies deze zodanig dat bij aanspreken van sealing agents are allowed on and in the valve. Feed tines and installation of other fillings- II is not permitted,
de veiligheidsklep tengevolge van de vaak zeer grole uitstroomvolumes geen personen gewond raken of according lo the rules, to install a dirt trap or shut-off valve in the feed line. Ensure sufficient cross-section of the
inrichtingen beschadigd worden. De veiligheidsklep moet toegankelijk zijn voor onderhoudswerkzaamheden en pipes! Weather protection- Take suitable measures to protect the device against snow, ice, and particulates.
mag niet uitsteken in de loopruimle.lnbedrijfstelling - Bij de eersle inbedrijfstelling moet de veiligheidsklep Roofs which do not hinder the outlet are suitable. Installation site- Select the site so that no injury to persons or
worden gevenlileerd! Om evt. aanwezige deelljes uit te blazen. Zie "Ventilatieprocedure". Waarschuwing- Let bij damage to property occurs when the SV is actuated due to the often very large quantities of discharged meium.
het ventileren op uw omgeving, zodat geen person en gewond raken of voorwerpen beschadigd worden door The SV must be accessible for maintenance work and not protrude into traffic areas. Initial operation- When
uitstromend medium. starting up for the first time, vent the SV! This is lo remove any particles which may be present. See also "Venting
WERKING/TOEPASSING Procedure." Caution - When blowing out the SV, be aware of your surroundings and ensure that no persons are
Gebrulk - De veiligheidsklep mag aileen voor zijn gebruiksdoel worden gebruikt. De werkdruk mag maximaal 15% injured or property is damaged by the escaping medium.
onder de insteldruk liggen. Onderhoud - Onderhoudsinlervallen moeten worden aangehouden. OPERATION/USE
ONDERHOUO EN tNSPECTIE Use- The SV is to be used only for its intended purpose. The max. permitted operating pressure is 15% below the
Let op gevaar voor verbrandlng - Veiligheidsklep en medium kunnen door werking heel worden - Draag setting pressure. Maintenance- Observe lhe required maintenance intervals!
lichaamsbescherming (handschoenen, veiligheidsbril). Onderhoudsfntervaf - Onderhoud moet worden uitgevoerd, MAINTENANCE AND INSPECTION
inlervallen worden overgelaten aan het oordeel van de gebruiker. Visuele inspectie- De veiligheidsklep moet Caution! Danger of Bum Injury! Th e SV and lhe medium can become very hot due to normal operation. Wear
worden gecontroleerd op vervuilingen en mechanische beschadigingen. Ventileren - Om vaslzittende vuildeelljes protective clothing (protective gloves, protective goggles). Maintenance interval - Th e SVs require periodic
los le maken, moet de veiligheidsklep eventueel met drukondersteuning worden geventileerd. Draag daarbij maintenance; the frequency of maintenance lies in the user's judgment. Visual Inspection -The SV must be
veiligheidsbril, gehoorbescherming en handschoenen. Het uitstromende medium kan vuildeelljes meeslingeren, er checked for contamination and mechanical damage. Venting -In order to discharge any contaminating particles, if
ontstaat lawaai- en temperatuurbelasting. Ventilatieprocedure- Zet de inslallalie onder druk, min. 80-90% van necessary, the SV is to be vented using compressed air. In doing so, you must wear protective goggles, hearing
de klepinstelling. Draai de ventilatieschroef enkele slagen naar links tot de veiligheidsklep afblaast. Daama moet protection, and gloves. The vented medium can convey particulate contamination. Noise and high temperatures will
deze weer lot de aanslag naar rechts worden gedraaid, zodat de klep weer dicht is. Reiniging met droge doek. Dek result. Venting- Pressurize the unit (at least 80-90% of the valve setting). Tum the venting screw a few turns
bij het reinigen van de complete installalie de veiligheidsklep af. Agressieve media kunnen de functie belemmeren. counter clockwise until the SV begins venting, then tum it back clockwise until the valve is again closed. Cleaning
REPARATIE/GARANTIE is performed with a dry cloth. When cleaning the entire installation, cover lhe SV. Aggressive media can impair the
Let op! Elke demontage van de veiligheidsklep is verboden. Door het losmaken van het loodzegel vervall de proper functioning of the SV.
garantie van de fabrikant en de loelating. Mechanlsche veranderingen - Openen van de klep of verandering van REPAIR/WARRANTY
de insleldruk aileen door fabrikant of geautoriseerde instiluten. Deze inbouw- en gebruiksaanwijzing moet bij de Attention! II is prohibited to dismount the SV in any way. Opening or otherwise tampering l~th the lead seal invalidates
keuring aan de keuringsexpert, bijv. TOv of DEKRA, worden overhandigd. the manufacturer's warranty and the unit's certilication. Mechanical modifications- Only the manufacturer or
authorized instiMions are allowed to open the valve ormodify the set pressure.These lnstal~tion and Operating
Markering zie voorzijde Instructions should be submitted to the examiner from the TOv or DEKRA Technical Inspectorate at acceptance.
Mark - see front
lrlP.nt Nr. ~001111 /1 ~ I 01 /1 n
 1 I 2 I 3 I 4 I 5 I 6 I 7 8

Sicherheitsventil. bauteilgeprUft. Typ 438 Safety-valve. type approved, Type 438

Anluftung H4, gasdicht 1
Werkstoff-Nr.: 1.4104. Chromstahl Material-no.: 1.4104, chromesteel
A A
lifting device H4. gastight
___ l ___ _
~-.J~~=-----------.-
Anschlungewinde Ein-1 Austritt: G 112 Connections inlet I discharge: G 112
Stromungsquerschnitt: do 10 Flow diameter: do 10
- i Dichtwerkstoff: FPM (Viton) Sealing material: FPM (Viton) -
Temperaturbereich: -20 °( bis +180 °( Temperature range: -20 °( bis +180 °(
\ i J
! Abblaseleistung Abblaseleistung
B B
I
0
Artikel-Nr. Einstelldruck Blow-off capacity Artikel-Nr. Einstelldruck Blow-off capacity
Article no. Adjusted pressure (Druckluft I air) Article no. Adjusted pressure (Druckluft I air)
I
i 0431113 6 bar 163 Nm31h 0204782 31 bar 730 Nm31h
- -
i
0
0260865 7.7 bar 230 Nm31h <Typ 439) 0333531 31.4bar I 455 PSI 730 Nm31h
! 0418045 7.75 bar 195 Nm31h 0362226 32 bar 765 Nm31h

c 0111106 8 bar 210 Nm31h 011286 7 33 bar 800 Nm31h c

0353468 9 bar 233 Nm31h 0417095 40 bar 963 Nm3/h
0236570 10 bar 257 Nm31h 0458876 41 bar 980 Nm3/h
-
0253948 10.5 bar 300 Nm31h <Typ 439) 0227095 42 bar 1000 Nm3/h -

045236 7 11 bar 280 Nm31h 0404580 44 bar Typ 4384, 1.4404:

1050 Nm3/h
N
......... 0453194 11 bar 316 Nm31h <Type 439)
D "'"" D
= _--+-----+-
0447010 12 bar 304 Nm31h
i
0374911 15 bar 374 Nm31h
i - -----+--+-----+-
-
i 0233506 27 bar 655 Nm31h -
= -~-----L-

i rn
rn
0112847 30 bar 727 Nm31h
I
I I
E I I E

! 14 Art.Nr. 0453194 dazu I 13.11.10 lscheppm.l 15 I 41 bar hinzu I 18.01.11 lscheppm.

And-Nr Anderung I Datum I Name IAnd-Nrl Anderung I Datum I Name
Datum Name Werkstoff-Daten Bez. laltl: NEUENHAUSER
- G 112 Gez. 19.10.01 Ladwig Nr: Bez. !DIN ENl: KOMPRESSORENBAU -
Gepr. 18.01.11 chepprr Halbzeug DIN Abmessung D-49828 NEUENHAUS
30 Status Freigegeben TELEFON 105941l 604-0
Schutzvermerk nach NHS TELEFAX 105941l 604-202
eMail NKIIneuenhauser.de
ISO 16016 beachten! PC 50 Internet www.neuenhauser.de
F ~----~--~----------------~~~~----~----~~~====~~F
Allgemein- Manstab Artikel-Nr.
toleranzen Sicherheitsventil Typ 438 -H4
Z. Nr. Ve_23015
ISO 2768-ml< 1:1 Safety valve type 438 -H4
Index 15 Blatt-Nr. 1 von: 1
Ersatz fUr:
Ersetzt durch:
1 I 2 I 3 I 4 I 5 I 6 I 7 8 A3
Instructions
Operating instructions
Betriebsanleitung
Instructions de service
Instrucciones de servicio
Ɋɭɤɨɜɨɞɫɬɜɨ ɩɨ ɷɤɫɩɥɭɚɬɚɰɢɢ

The-Safety-Valve.com
 Operating Instructions

EN Content

1 Introduction ............................... 3 6 Installation ................................. 9

1.1 Manufacturer ............................... 3 6.1 General information about

1.2 About this User Guide ................. 3 installation ................................... 9
1.3 Illustration conventions ............... 3 6.2 Safety valve installation............. 11

2 Safety ......................................... 4 7 Start-Up.................................... 12

2.1 Proper Use .................................. 4 7.1 Starting up the system .............. 12

2.2 Improper Use .............................. 4
2.3 Standards and Technical 8 Operation ................................. 12
Guidelines ................................... 5
2.4 Basic Safety Guidelines .............. 5 8.1 General information about
operation ................................... 12
3 Marking ...................................... 7 8.2 Checking the operation of the
safety valve ............................... 13
4 General Information 8.3 Safety valve inspection ............. 13
on Safety Valves ........................ 8
9 Maintenance ........................... 14
4.1 Gaskets and leaks....................... 8
4.2 Drainage ...................................... 8 9.1 General Information about
4.3 Operating pressure and maintenance.............................. 14
set pressure ................................ 8 9.2 Setting the set pressure ............ 15
4.4 Ambient conditions ..................... 8 9.3 Replace Spring.......................... 16
4.5 Protective coating ....................... 9

5 Packaging, Transport
and Storage ............................... 9

5.1 Packaging ................................... 9

5.2 Transport ..................................... 9
5.3 Storage........................................ 9

2
Operating Instructions

1 Introduction EN
1.1 Manufacturer

LESER manufactures safety valves for all In addition to the information in this user’s
industrial applications. A large selection of guide, the generally applicable safety and
types, materials and options are available. work safety regulations must also be ob-
served. In like manner, the environmental
Safety valves from LESER fulfil all quality protection regulations must be adhered to.
and environmental requirements.
1.3 Illustration conventions
LESER is certified according to:
• DIN EN ISO 9001/2000 Safety guidelines and warnings identify
(quality management system), safety-relevant information. This user’s
• DIN EN ISO 14001/2005 guide differentiates between the following
(environmental management system), risk levels:
• Pressure Equipment Directive Module
B+D1 (quality assurance in production), DANGER
• ASME VIII (UV), This identifies the highest risk situation. If
• KTA 1401. the guidelines are not observed, the result
will be serious injury or death.
1.2 About this User Guide
WARNING
This user’s guide covers the following ty- This identifies a high risk situation. If the
pes of safety valves and peripheral devices guidelines are not observed, the result may
in summary form: be serious injury or death.
• spring-loaded safety valves (A),
• pilot-operated safety valves (B), CAUTION
• supplementary loaded safety valves (C). This identifies a risky situation. If the gui-
delines are not observed, the result may be
Safety valves can also be equipped with minor or medium injuries.
bursting discs, pneumatic supplementary
loading, bellows and upstream change- CAUTION
over valves. This identifies warnings regarding material
damage. If the guidelines are not obser-
Certain regulations and standards apply ved, the result may be material damage.
depending on the system and medium.
These regulations and standards must be
observed.

3
 Operating Instructions

EN The safety guidelines and warnings are The maximum permissible operating pres-
organised as follows: sure depends on several factors, including:

Source of the danger • the material of the safety valve,

• the temperature of the medium,
Consequences if the danger is disregarded • the design pressure,
• the flange rating class.
• Measures to counter the danger and to
prevent injuries. The approval document must be used to
check whether the right safety valve has
been selected for the designated use.
The basic safety guidelines are summa-
rised in chapter 2.4. Warnings are found in Dependent on the system, specific
the handling instructions. threshold values for the temperature of
the medium apply. The safety valve spring
Individual paragraphs that only apply to must be configured accordingly. The set
specific types of safety valves, are identi- pressure must be adjusted accordingly.
fied with a letter.
When working with dangerous or harm-
The following letters are used for marking ful media, the respective regulations and
paragraphs: standards must be observed.

• A for spring-loaded safety valves, Dangerous media includes:

• B for pilot-operated safety valves,
• C for supplementary loaded safety • toxic media,
valves. • caustic media,
• irritating media,
2 Safety • environmentally hazardous media,
• hot media.
2.1 Proper Use
Safety regulations and warnings must be
Safety valves come in different designs. observed.
When choosing a safety valve, the desig-
nated purpose must be taken into consi- 2.2 Improper Use
deration.
Safety valves must not be used improperly.
A safety valve is designed for operation In the event of improper use, the manufac-
within a specific pressure range. turer is no longer liable.

Seals must not be damaged or removed.

4
Operating Instructions

Changes may affect the operation of the 2.4 Basic Safety Guidelines EN
safety valve. The guarantee is voided.
Moving and functionally important parts DANGER
must not be given a protective coating. Dangerous media

Safety valves – especially the actuator and Poisoning, caustic burns, burns, injuries
coupling – must not be blocked.
• Use suitable protective devices
Levers on safety valves must not be used • Use suitable collecting tanks.
as hangers for any objects. The position of • Wear suitable protective equipment.
the lever must not be changed. No additi-
onal weight may be applied to the levers. Foreign bodies in the safety valve

2.3 Standards and Technical Danger from failure of safety valve or leaks
Guidelines
• Flush the system before installation
The safety valves are state of the art at the of a safety valve.
time of delivery. • Check the safety valve for foreign
objects.
The following standards and regualtions • Remove foreign objects
must be observed when working with sa-
fety valves: Bug screen is damaged or missing
(B or option)
• TRD 421, 721,
• TRB 403, Dirt, objects or insects get into the
• AD 2000 Merkblatt A2 and A4, safety valve. Danger from malfunction of
• DIN EN ISO 4126, the safety valve.
• Pressure Equipment Directive 97/23/EU
• ASME Code, Section II and VIII, • Install the bug screen correctly.
• API 520, 526, 527, • Check the bug screen regularly.
• ATEX 100.

Other standards and regulations must be

observed depending on the use of the
safety valve.

The standards and technical guidelines

that are fulfilled by a specific type of safe-
ty valve can be found in the declaration of
conformity.

5
 Operating Instructions

EN Ambient temperature is too high Abrasive or corrosive media

Material expansion. Danger from malfunc- Moving parts jam or become stuck. Danger
tion of the safety valve. from functional disruption of the safety valve.
• If temperatures are above 60 °C, then • Service the safety valve after each time
configure pressure tapping lines to be it opens.
as long as possible and with a water • Use bellows.
seal (only C).
• Position the control cabinet and actu- Media with high proportion of particles
ators so that they are not subjected to (only B)
temperatures higher than 60 °C (only C).
Deposits and clogging. Danger from mal-
Ambient temperature is too low function of the safety valve.

Icing, freezing vapours, reduced flow rate • Use a filter with the correct mesh size.
due to congealing media. Danger from • Use additional filters to increase the
functional disruption of the safety valve. filter capacity.
• Protect safety valve and pipelines from
cold (only C). Residual media in the safety valve
• Take the appropriate measures for
temperatures below 2 °C (only C). Poisoning, caustic burns, burns, injuries
• Heat the control cabinet and pressure
tapping lines for temperatures below • Wear suitable protective equipment.
2 °C (only C). • Remove residual media

Pressure range of the air supply excee- WARNING

ded or not reached (only C) Leaky safety valve

Malfunction or supplementary loading. Danger from leaking media due to dama-

Danger from functional disruption of the ged gaskets and sealing surfaces.
safety valve.
• Protect the safety valve against vib-
• Comply with the pressure range of the air rations and blows especially during
supply: transport and installation.
– Maximum pressure: 10 bar, • Check safety valve regularly for leaks.
– Minimum pressure: 3.5 bar.

6
Operating Instructions

Open bonnet or spindle guides High noise emission EN

Danger from leaking media Hearing damage.

• Make sure that no danger can arise from Wear ear protection.
leaking media.
• Keep a safe distance.
• Wear suitable protective equipment. 3 Marking
CAUTION After setting and testing, each safety valve
Hot medium is sealed. Only if the seal is undamaged is
it assured that the safety valve will operate
Burns or scalding. in accordance with the marking.

• Wear suitable protective equipment. The component marking attached to the

safety valve (type plate) provides infor-
Hot surfaces mation about the following, among other
things:
Burns. • order data (serial number),
• technical data,
• Wear suitable protective equipment. • set pressure
• VdTÜV component test number,
Aggressive medium • CE marking with number of the speci-
fied centre,
Caustic burns. • UV marking if applicable.

• Wear suitable protective equipment. Other markings can be applied in ac-

cordance with the requirements of the ap-
Open bonnet or spindle guides plied standards, for example:
• marking with a marking stamp
Pinching danger from moving parts. • cast marking,
• hammered-in marking
• Install suitable safeguards. (e.g. for threaded safety valves)
• separate marking
Sharp edges and burrs (e.g. for the heating jacket),
• warning tags (e.g. for a test gag).
Danger of injury.
If there are technical changes to a safety
• Wear safety gloves. valve, then the markings must be chan-
• Handle the safety valve carefully ged as well.

7
 Operating Instructions

EN 4 General Information installation on ships). Safety valves can

on Safety Valves be ordered with a drainage opening. Even
afterwards, a drainage opening can be
4.1 Gaskets and leaks drilled at the spot designated for it. The re-
spective drawings must be requested from
Safety valves are manufactured with high the manufacturer.
precision. Above all, the sealing surfaces
of the safety valves are processed very Drainage openings that have no function
carefully. must be sealed.

Soft sealing and metallic sealing safety 4.3 Operating pressure and
valves are differentiated. set pressure

Metallic sealing safety valves fulfil the seal In order to guarantee reliable closing
tightness requirements of the national and after a safety valve opens, system ope-
international standards. rating pressure must continuously remain
below the set pressure.
A variety of elastomer materials are of-
fered for soft sealing safety valves. The The operating pressure must be at least
elastomer material must be selected in the value of the closing pressure difference
accordance with the area of application. plus 5% below the set pressure.
The choice is dependent on the medium,
pressure and temperature. The clamping force of a spring-loaded
safety valve drops as the operating pres-
A check gauge can be used to detect sure increases. The closer the opera-
leaks. For spring-loaded safety valves,. ting pressure is to the set pressure, the
bellows can be used to prevent media more likely it is for the medium to escape
from leaking out. (only A). This may result in leaks especially
if the sealing surfaces are damaged or
A collecting tank can be used to collect dirty.
any leaking media.
If the compressed air for the supplementa-
4.2 Drainage ry loading fails, then the safety valve func-
tions just like a conventional safety valve
As a rule, safety valves are delivered without supplementary loading (only C).
without a drainage opening because the
drainage must take place via a blow- 4.4 Ambient conditions
off line. Only in exceptional cases are
drainage openings permitted or even re- The controllers and actuators are designed
quired directly in the safety valve (e.g. for for use between 2 °C and 60 °C.

8
Operating Instructions

Safety valves made of stainless steel are tions and impacts may damage the sealing EN
recommended for use under extreme con- surfaces.
ditions.
Safety valves must be protected against
The safety valves and pipelines must be soiling during transport. Protectors and
protected from atmospheric influences. suitable packaging must be used.

4.5 Protective coating 5.3 Storage

Safety valves are given a protective coa- Safety valves must be stored in a dry area
ting at the factory. The protective coating and protected against soiling.
protects the safety valve during storage
and transport. If the external conditions The safe storage temperature is between 5
are corrosive, then additional corrosion °C and 40 °C.
protection is necessary.
The upper limit for the storage temperature
Moving and functionally important parts is 50 °C, and the lower limit is -10 °C.
must not be given a protective coating.
Safety valves are equipped with flange
5 Packaging, Transport protection caps at the factory. These flan-
and Storage ge protection caps must be in place during
storage.
5.1 Packaging
If safety valves are stored at temperatures
Safety valves are checked for damage and below zero degrees, then the temperature
leaks before delivery. For safe transport, all resistance of the materials (e.g. of seals)
sealing surfaces, sealing lips and threads must be taken into consideration.
must be protected against damage using
protectors. 6 Installation

5.2 Transport 6.1 General information about

installation
Safety valves may only be lifted by the ring
nuts provided for transport (only B). Only trained personnel may install safety
valves.
Safety valves must not be lifted by the ven-
ting lever or by any outside piping. Training can be obtained via LESER semi-
nars, from experienced personnel in work-
Safety valves must be transported careful- shops, or by studying the documentation
ly. Safety valves must not fall over. Vibra- provided by LESER such as video films,

9
 Operating Instructions

EN catalogues and installation guides. Be- valves. The connections must be configu-
sides this general user’s guide, there are red in accordance with the specifications
also type-specific installation guides. Tho- defined in standards and regulations.
se installation guides must be observed.
The supply lines and blow-off lines of the
Safety valves must be secured in ac- safety valve must be dimensioned ade-
cordance with the specifications in the dra- quately and adapted to the local operating
wings. All designated fastening elements conditions. The maximum occurring back
must be used so that no excessively high pressure and the temperature must be ta-
forces or mechanical stress may arise. ken into account.

Torque requirements must be adhered to. Ma- Safety valves must be installed so that no
nufacturer specifications must be observed. inadmissibly high static and thermal stress
can be transferred to the safety valve from
Safety valves – especially the sealing sur- the supply and discharge lines. During the
faces – must be protected against impacts installation, any occurring reaction forces
during the installation. during the blow-off and any temperature
expansion during operation must also be
As a rule, safety valves must be installed taken into consideration. Expansion pos-
in an upright position. Exceptions are only sibilities must be provided to compensate
permissible if other installation positions for this.
are described in the certification docu-
ments. A horizontal installation position The blow-off lines must be installed in a
must be agreed on by the operator, manu- way that is flow-optimised. Depending
facturer and an expert. on the designated use, the blow-off lines
must have different discharge directions.
Safety valves must be installed in such a There is a differentiation between dischar-
way that dynamic vibrations in the system ge lines for steams or gasses and dischar-
cannot be transmitted to the safety valves. ge lines for fluids.
If the system is not vibration free, then
bellows, O-rings or U-shaped expansion The discharge line for discharging steams
pipes are suitable for decoupling the safe- or gasses must be attached such that they
ty valves from the system. rise upward in order to guarantee dischar-
ging without any danger.
Safety valves with cast support brackets
must be secured to the system. The sup- In order to drain the discharge line, the di-
port brackets absorb the reaction forces. scharge line must be attached such that
it has a downward slope to the draina-
Adequately dimensioned gaskets must ge opening at the lowest point. Correct
be used on the connections of the safety drainage is only possible if the discharge

10
Operating Instructions

line directly behind the safety valve has a The control cabinet must be closed. If soi- EN
downward slope so that the medium can ling cannot be excluded, then an encapsu-
completely drain off. The discharge line lated control cabinet must be used (only C).
should not have an upward slope directly
behind the safety valve. If a safety valve with a bursting disc is
used, then make sure that the safety valve
The drainage opening must be placed at is not rendered ineffective by the upstream
the lowest point of the discharge line. The bursting disc. Structural measures must
drainage opening must be dimensioned be taken to make sure that it is not pos-
adequately and be freely accessible with sible for the bursting disc to be aligned
a possibility to be monitored. Escaping incorrectly.
media must be collected (e.g. through
condensate collectors, collecting tanks or Bursting discs may only be used if they
filters). satisfy the safety requirements. Evidence
that the bursting discs are fragment-free
If, as an exception, a drainage opening is must be provided.
placed directly on the safety valve, then it
must be protected by safeguards so that 6.2 Safety valve installation
neither moisture nor dirt can get in.
Different installation steps are required, de-
If the system is operated at temperatu- pending on the system and type of safety
res greater than 60 °C, then the pressure valve. Only the essential installation steps
tapping lines of the supplementary loaded are summarised and given in the following
safety valves must be as long as possible handling instructions. The handling instruc-
and have a water seal. The control cabinet tions are only intended to provide a rough
and actuators must be placed such that orientation. Specific details must be taken
they are not subjected to temperatures from the type-specific installation guides.
higher than 60 °C (only C).
Prerequisites
There is a danger of icing at temperatures
below 2 °C. For lower temperatures, the • The safety valve has been identified
control cabinet and pressure tapping lines based on the type plate.
must be heated (only C). • A visual check of the system has been
performed.
Pressure tapping lines must not be blo- • Connections have been checked for
cked. Locking rails or seals prevent blocks seal tightness.
from being closed (only C). • The system has been flushed in order to
make sure that no impurities or foreign
The control cabinet for the supplementary objects have gotten into the safety
loading must be protected against soiling. valve.

11
 Operating Instructions

EN • For safety valves without a test gag, the 3. Remove the test gag.
pressure test of the system is performed 4. Secure the blow-off chamber.
with a blind flange or sealing plate. 5. Start the system slowly, and increase
the pressure slowly but not up to the
Procedure set pressure.
6. Check the safety valves and connec-
• Secure the safety valve. If there are sup- tions for leaks.
port brackets, then they must be used.
• Attach the supply and discharge lines. » The system is now in operation.
Use adequately dimensioned gaskets.
• If necessary, provide drainage for the 8 Operation
discharge line.
• If necessary, place a drainage opening 8.1 General information about
at the lowest point of the discharge line. operation
• Remove securing devices from safety
valve. During operation, the operability of the sa-
fety valve must be checked regularly.
» The safety valve is now installed.
For pilot-operated safety valves, the pilot
7 Start-Up lifting device, the main valve lifting de-
vice or the pilot test connector (FTC) can
7.1 Starting up the system be used for testing the set pressure. The
test connector must always be accessible
Different steps are required for the start- (only B).
up, depending on the system and type of
safety valve. Only the essential steps for Safety valves must be vented to test their
start-up are summarised and given in the operation. Safety valves can be vented
following handling instructions. The hand- starting at an operating pressure of 75%
ling instructions are only intended to provi- of the set pressure. Maintenance intervals
de a rough orientation. must be taken from governing regulations
and standards.
Prerequisites
Testing can take place during operation
» The safety valve is installed. for pilot-operated safety valves equipped
with a pilot test connection. The correct
Procedure test medium must be used. After the pilot
executes the switching operation, the main
1. Perform a pressure test on safety valve lifts. In the process, the medium must
valves with a test gag. be drained off safely. After testing, check if
2. Check the position of the venting lever. the safety valve is leak-free. The pilot test

12
Operating Instructions

connection must again be secured against steps are summarised and given in the fol- EN
impurities using the sealing cap (only B). lowing handling instructions. The handling
instructions are only intended to provide
For pilot-operated safety valves without a a rough orientation. The details must be
pilot test connection, the test must be per- taken from the type-specific guides.
formed on a test bench (only B).

The safety valve must be cleaned if the WARNING

safety valve is leaky because of impurities For media discharging at high speed,
between the sealing surfaces. In this case, high temperature and high loudness
the safety valve must be vented and the level
medium blown out.
Danger of injury and hearing damage
If the safety valve is leaky because of a
damaged sealing surface, then it must be • Wear protective equipment.
serviced. • Wear ear protection.

Vibrations in the system may cause com- Procedure

ponents to become loose. Screw connec-
tions must be checked regularly. 1. Vent the safety valve.
2. If applicable, check the supplementary
Maintenance intervals are dependent on loading (only C).
the conditions of use. Therefore, for all sa- 3. Blow-out medium.
fety valves there are separate maintenance 4. Remove deposits.
intervals that must be defined in an agree- 5. Check whether the movable guide
ment with the operator, manufacturer and surfaces or soft seals are stuck.
by a specified centre. 6. Check whether the venting lever is
freely accessible.
Maintenance intervals become shorter if: 7. Check the drainage operation.
• corrosive, aggressive or abrasive media
are used, a safety valve opens frequently. » The safety valve has now been
• Supplementary loading systems must inspected.
be checked at least once a year.
8.3 Safety valve inspection
8.2 Checking the operation of the
safety valve Different steps are required for testing du-
ring operation, depending on the system
Different steps are required for testing du- and type of safety valve. Only the essenti-
ring operation, depending on the system al steps are summarised and given in the
and type of safety valve. Only the essential following handling instructions.

13
 Operating Instructions

EN The handling instructions are only inten- The safety valve must be dismounted for
ded to provide a rough orientation and only maintenance work. Dismounting may be
apply to pilot-operated safety valves (B). more difficult if the lubricants have been
The details must be taken from the type- washed out.
specific guides.
Pressure must be released from the sys-
Procedure tem before dismounting.

1. Check exterior pipelines for damage. Before disassembly, check whether there
2. Check screw connections. is any medium in the bonnet. If any me-
3. Clean pressure tapping and control dium is leaking from the open bonnet or
lines. the drainage opening, then the bellows is
4. Check attachments for damage. faulty. Faulty bellows must be replaced im-
5. Check the clearance of the mediately.
attachments.
6. Clean the filter in front of the pilot Bellows should be checked when disas-
regularly. sembling the safety valve and always re-
7. Clean additional filters regularly. placed if there is any damage.

» The safety valve has now been Bellows have a limited number of load
inspected. reversals. The bellows must be replaced
when that number of load reversals has
9 Maintenance been reached.

9.1 General Information about Gaskets and gasket points must be che-
maintenance cked regularly. If the seal tightness require-
ments are no longer fulfilled, then the gas-
Only trained personnel may maintain safe- kets must be replaced. Spare assemblies
ty valves. can be ordered from LESER.

Training can be obtained via LESER semi- If the set pressure is to be changed, then
nars, from experienced personnel in work- the spring table must be used to check
shops, or by studying the documentation whether the spring may be used. The cor-
provided by LESER. rect spring for the designated set pressure
must be used. After the set pressure has
Anyone who disassembles safety valves been changed, the configuration of the en-
must be informed of the dangers. tire safety valve must be checked.

LESER’s worldwide network provides The seal must be removed to adjust the
maintenance services. set pressure and to replace the spring.

14
Operating Instructions

This voids the guarantee. Changes should Prerequisites EN

be made in the factory, by an authorised
workshop, or by a specified centre. • Ensure the system is not under pressure.
• There must not be any media in the
9.2 Setting the set pressure bonnet of the safety valves.

Different steps are required for the disas- Procedure

sembly, depending on the system and
type of safety valve. Only the essential 1. Break the seal.
steps are summarised and given in the 2. Remove the lever cover.
following handling instructions. The hand- 3. Secure the spindle against twisting.
ling instructions are only intended to pro- 4. Tighten the spring and adjust the pres-
vide a rough orientation and only apply to sure screw to the desired set pressure.
basic safety valves without special Observe the permissible adjustment
options. The details must be taken from range of the spring when doing so.
the type-specific guides. – The set pressure becomes higher when
the pressure screw is turned to the right.
WARNING The spring is put under more tension.
Leaking Medium – The set pressure becomes lower when
the pressure screw is turned to the left.
Danger to persons and the environment. The tension on the spring is relieved.
5. Check the set pressure.
• Take safety measures in accordance 6. Install the lever cover.
with the medium. 7. Have the safety valve resealed by an
• Capture the medium from the pipelines. authorised centre.
• Do not allow unauthorised persons in
the danger zone. » The set pressure has now been set.
• Wear suitable protective equipment.

CAUTION
Spindle is not protected against
twisting

Damage to the sealing surfaces

• Secure the spindle against twisting.

15
 Operating Instructions

EN 9.3 Replace Spring

CAUTION
Different steps are required for the disas- Spindle is not protected against
sembly, depending on the system and twisting
type of safety valve. Only the essential
steps are summarised and given in the fol- • Damage to the sealing surfaces
lowing handling instructions. The handling • Secure the spindle against twisting.
instructions are only intended to provide a
rough orientation and only apply to spring-
loaded safety valves without options (A).
The details must be taken from the type-
specific guides.

WARNING
Leaking Medium

Danger to persons and the environment.

• Take safety measures in accordance
with the medium.
• Capture the medium from the pipelines.
• Do not allow unauthorised persons in
the danger zone.
• Wear suitable protective equipment.

WARNING
Spring is under tension

Risk of injury from parts flying around.

• Observe the installation instructions for
the safety valve.
• Wear protective equipment.

WARNING
Inverted springs

Blocked springs.
Loss of operation.
• Do not invert springs when taking
the safety valve apart.

16
Operating Instructions

Procedures (only A) EN
1. Break the seal.
2. Remove the lever cover.
3. Secure the spindle against twisting.
4. Raise the pressure screw.
5. Remove the bonnet.
6. Remove the spring.
7. Remove the spindle with the guide
and disc.
8. Clean the seat, disc, and body.
9. Reinstall the spindle with the guide
and disc.
10. Insert new spring.
11. Put the bonnet back on.
12. Secure the spindle against twisting.
13. Tighten the spring and adjust the
pressure screw to the desired set
pressure. Observe the permissible
adjustment range of the spring when
doing so.
– The set pressure becomes higher
when the pressure screw is turned
to the right. The spring is put under
more tension.
– The set pressure becomes lower
when the pressure screw is turned
to the left. The tension on the spring
is relieved.
14. Check the set pressure.
15. Install the lever cover.
16. Pull the venting lever to the middle so
that the lifting fork engages under the
coupling.
17. Have the safety valve resealed by an
authorised centre.

» The spring has now been replaced.

17
 2 3 4 5 7 8

ra1n 1nlet

A pressure compension line A

for air-return

(~)

B B
20_1 1- drain-outlet
376
ball-float-trap G1/2 - PN 40 I horizontal ZR
263 113 inlet on r1ght side

[ -------- [

N
~
m
N
-t-1- N

b~/>~sf·
N I
Ln
C) ~ N
[--
~
I
C)
----€>---- ----€>----
'-0
I I

D 100 6
90 6
420
so
70 6
60 1
so
40 2
30 3
20 2
10
Pos. Stk.
pos. p ece
1

E Ln
7 Modelmod f kat ion lAb lass unten !l 26.04.2016 Bhs
m 1 1

6 10.06.2015 Bhs
17 .03.201S Bhs
Index Anderung Datum Name
PC SO Datum Name Werkstoff -0 aten Bez .:
Gez. 06.06.2008 Scheppm. Nr. Bez. ID IN EN): NEUENHAUSER
Gepr.
Status
27.04.2016

Schutzvermerk nach
Bhs

Freigegeben

f------=-~------c--c--- D I N- Norm
D1N 1so 16016 beach ten!
Halbzeug-0 aten
Halbzeug:

EN-Norm:
Halbzeug-Nr .:

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON (05941) 604-0
TELEFAX (05941) 604-202
e-mail NK©neuenhauser .de
F Ma Bstab Art. Nr. 10223S2 F
Toleranzen fur Schwe 1Sbaugruppen Baugruppe Beh ill terentw asserung Z. Nr. Zu_3071S
EN I SO 13920-D 1S
float trap dra n assembly 1

Index 7 Blatt -Nr. 1

weight: approx, 13 kg (empty) Allgeme 1ntoleranzen m1t Schw immerkondensatable iter
Ersatz fur
DIN I SO 2768-mK Ersetzt durch
ZU_3071S-0-7 2 3 4 5 6 7 8 A3
 2 3 4 5 6 7 8

A A

-t71-
B B
CXJ
CXJ
N

-t-+-1-
1

[ +0
[

100
200
ra1n inlet weight: approx, 13 kg (empty)
D D
100 6 Zyl-Schraube m I nnenSkt socket head screw OOS1404
90 6 Scheibe Form A washer 0072039
so Hal teblech 430x200x6 support plate 1034936
70 6 Distanzblech BOx40xS plate 1021741
60 1 Rundstahlrohr nahtl seamless p 1pe 0286774
ressure compensation l1 ne so Rohrschelle RAP S-112 pipe clip 1021743
for air return 40 TR 12108112 L - 71 fitting 0394988
30 2 Rundstahlrohr nahtl 12 ,Ox2 ,0/1.4301 drain p1pe OOS4432
20 2 GE 12-L/ R112 - ED - 71 fitting, stainless steel 0394987
10 Schwimmer Kondensatable 1ter Typ BR630 Float trap condensate discharge un1t 02177 47
Pos. Stk. Benennung description Art. Nr.
E pos. p 1ece art. no. E
Modelmod 1f 1kat ion lAb lass unten !I 09 .OS .2016 Bhs
0 09.09.2009 Scheppm.
Index Anderung Dalum Name
PC SO Dalum Name Werkstoff -0 aten Bez .:
Gez. 09.09.2009 Scheppm. Nr .: Bez. ID IN EN I: NEUENHAUSER

drain outlet
ball-float trap G1/2 - PN 40
vertical - inlet from top
Gepr.
Status
o9.os.2016 Bhs

Freigegeben

f------=-~------c--c--- D I N- Norm
Schutzvermerk nach
D1N 1so 16016 beach ten!
Halbzeug-Daten
Halbzeug:

EN-Norm:
Halbzeug-Nr .:

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON IOS9411 604-0
TELEFAX IOS9411 604-202
e-mail NK©neuenhauser .de
F Ma Bstab Art. Nr. 1034940 F
Toleranzen fur Schwe I Sbaugruppen Baugruppe Behaelterentwaesserung Z. Nr. Zu_30962
EN I SO 13920-D 15
float trap dra n assembly1

Index 1 Blatt -Nr. 1

Allgeme 1ntoleranzen m1t Schw immerkondensatable iter
Ersatz fur
DIN I SO 2768-mK Ersetzt durch
ZU_30962-0-1 2 3 4 5 6 7 8 A3
 Operating and installation instructions
Ball float steam traps
CONA®S (PN16 - 40)

PN40
- with flanges (series 630....1)
- with screwed sockets (series 630....2)
PN16 - with socket weld ends (series 630....3)
- with flanges (series 630....1) - with butt weld ends (series 630....4)

Contents
1.0 General information on operating 5.5 Installation position................................................. 8
instructions ..................................................... 2 5.5.1 Possible installation positions .................. 8
2.0 Notes on possible dangers............................ 2 5.5.2 Installation with pressure compension line 9
2.1 Significance of symbols ..........................................2 6.0 Putting the valve into operation ................... 9
2.2 Explanatory notes on safety information .................2 7.0 Care and maintenance................................. 10
3.0 Storage and transport ................................... 2 7.1 Cleaning / replacing controller assembly.............. 10
4.0 Description...................................................... 3 7.2 Changing the installation position..........................11
4.1 Scope of application................................................3 7.3 Options blow down valve /
manual air vent valve ........................................... 12
4.2 Operating principles ................................................3
7.4 Union for pressure compension line /
4.3 Diagram...................................................................4
external vent......................................................... 12
4.4 Technical data - remarks .........................................5
7.5 Tightening torques................................................ 13
4.5 Marking ...................................................................5
8.0 Troubleshooting ........................................... 13
5.0 Installation....................................................... 6
9.0 Troubleshooting table ................................. 14
5.1 General notes on installation...................................6
10.0 Dismantling the valve or the body ........... 15
5.2 Installation instructions for welding .........................7
11.0 Warranty / Guarantee ................................. 15
5.3 Controller adjustment ..............................................7
12.0 EC declaration of conformity .................... 16
5.4 Steam trap testing through
ultrasonic measurement..........................................7

Rev. 0040805002 4608 englisch

 Operating and installation instructions
CONA®S - Ball float steam traps

1.0 General information on operating instructions

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

2.2 Explanatory notes on safety information

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

3.0 Storage and transport

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valves must not be used to take external forces, e.g. they are not designed for
use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- Transport and store the other way up from operating position (upside down).
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage.
Do not damage paint protection.

Page 2 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps

4.0 Description
4.1 Scope of application
Float-type steam traps with level control are used for the drainage of systems with
compressed air or aqueous gases.

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

4.2 Operating principles

(refer to Fig. 5 page 11)
The steam trap is controlled by a swivel-mounted ball float (Pos. 24.16). If condensate is
flowing into the steam trap, the ball float (Pos. 24.16) floats up and opens the discharge
valve via a lever mechanism. Once the valve is open, the differential pressure between the
steam and condensate systems forces the condensate out through the valve.
If the amount of condensate decreases or if there is no condensate, the ball float
(Pos. 24.16) falls and shuts the discharge valve.
The valve ball (Pos. 24.4) also works with the seat (Pos. 24.1) as a non-return valve.
The condensate must be able to flow towards the valve at a constant gradient. If there is a
possibility that the trap could be air locked, a pressure compensation line must be led back
to the system from the top of the hood to guarantee safe functioning of the controller (see
Fig. 4).

Rev. 0040805002 4608 Page 3

 Operating and installation instructions
CONA®S - Ball float steam traps
4.3 Diagram

Fig. 1: CONA®S - series 630 PN16

Fig. 2: CONA®S - series 630 PN40

Refer to the data sheet for information about materials with designations and figure numbers.

Page 4 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps
4.4 Technical data - remarks
for
- Principal dimensions,
- Pressure-temperature-ratings, operating limits,
- Valves with different types of connection , etc.
refer to datasheet.
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0045 Notified body
AWH Manufacturer Anschrift des Herstellers:
siehe Pkt 11.0 Garantie / Gewährleistung
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive appendix 2 diagram 7 valves acc. to article
1 paragraph 2.1.2 (pipes) only show the CE-marking from DN40 onwards.

Rev. 0040805002 4608 Page 5

 Operating and installation instructions
CONA®S - Ball float steam traps

5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- It is possible to install the float steam trap for vertical or horizontal flow. Note
installation position with reference to flow, see mark on valve.
- Steam and air line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate precisely.
- Valves must not be used to take external forces, e.g. they are not designed for
use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See data sheet for weights.
- Centre gaskets between the flanges.
- Precautions against freezing should be taken as a matter of course in any
facilities susceptible to frost. If a system not in operation is in a position
susceptible to freezing, we recommend that the drain plug (Pos. 50) on the
unpressurised steam trap be unscrewed, the residual condensate drained off,
the seal faces cleaned and the plug screwed down again.
The sealing ring (Pos. 49) should be replaced if necessary.
(see Fig. 1 - Fig. 2 page 4)
- Planners / construction companies or operators are responsible for positioning and
installing products.
- The valves are designed for application, not influenced from weather.
- For application outside or in adverse environments like corrosion-promoting conditions
(sea water, chemical vapours, etc.), special constructions or protective measures are
recommended.

Page 6 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps
5.2 Installation instructions for welding
(refer to Fig. 2 page 4)
Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Please refer to the catalogue sheet for information on type and instructions relating to
welding socket weld ends/butt weld ends.
When welding products to the pipeline system they should be adequately cooled to prevent
any adverse effect on the complete controller assembly (Pos. 24) or possibly the flat gasket
(Pos. 17). The heat-affected zone should be restricted to the immediate weld seam area!
Note pre- and post-welding heat treatment in accordance with Material Fact Sheet
DIN EN 10222.

5.3 Controller adjustment

The controller is set by the manufacturer as stated in the order and does not need
changing. Should the operating parameters have changed fundamentally compared with
the particulars in the order, please contact the manufacturer to change the controller
adjustment!

5.4 Steam trap testing through ultrasonic measurement

Testing the operation of the steam trap in the installed state is straightforward with the
“ARImetec®-S” mulitfunctional testing device.
Refer to data sheet “ARImetec®-S”.

Rev. 0040805002 4608 Page 7

 Operating and installation instructions
CONA®S - Ball float steam traps
5.5 Installation position
(refer to Fig. 3 and Fig. 5 page 11)
The float steam trap can be installed for vertical or horizontal flow. This should be stated
when ordering.
If the installation position is not stated it will be supplied for vertical flow.
It is possible to change the installation position at a later stage (see 7.2).
However the steam trap must always be installed so that the ball float (Pos. 24.16) can
work in a vertical plane.

ATTENTION !
The union for the pressure compensation line (Pos. 52) at the hood
(Pos. 16) must point up!

5.5.1 Possible installation positions

Horizontal installation:
Inlet from the left side (ZL)

Vertical installation (standard): Horizontal installation:

Inlet from the top Inlet from the right side (ZR)

Fig. 3

Page 8 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps
5.5.2 Installation with pressure compension line
ATTENTION !
The installation of a pressure compensation line for gas return is always
recommended; especially if the ball float steam trap is installed
horizontally.

Pressure compension line

Product line for gas return

Steam, air Steam, air

or gas with or gas
condensate

Condensate
Collector line for
condensate
Stop valve Stop valve

Valve for drainage of dirt Ball float steam trap

horizontal installation

Fig. 4

6.0 Putting the valve into operation

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

Rev. 0040805002 4608 Page 9

 Operating and installation instructions
CONA®S - Ball float steam traps

7.0 Care and maintenance

Maintenance and maintenance intervals have to be defined by the operator according to
the requirements.

ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work !
- refer to item 6.0 before restarting the plant !
Prior to installation, threads and seal faces should be coated with temperature-
stable lubricant (e.g. “OKS Anti-Seize Paste” white/metal-free)

7.1 Cleaning / replacing controller assembly

(refer to Fig. 1- Fig. 2 page 4 and Fig. 5 page 11)
- Dismantle hood (Pos. 16) by slackening hexagonal nuts (Pos. 28).
- Slacken union (Pos. 52) to remove pipeline at pressure compensation line.
- Remove dirt from body (Pos. 1) and hood (Pos. 16); tiny dirt particles can be removed by
flushing out the ducts and rinsing the body (Pos. 1). Clean the strainer (Pos. 2).
- If necessary dismantle the float controller (Pos. 24) and clean separately or change float
controller.
- Unscrew the hollow-core screw (Pos. 24.10) of the float controller (Pos. 24) from the body
(Pos. 1).
- Pull complete float controller (Pos. 24) out to remove, taking care with the sealing ring
(Pos. 11).
- Do not make any changes to spindle adjustment (Pos. 24.3), the float controller (Pos. 24)
is set by the manufacturer (except in the case of extremely high back pressures, when
please consult the manufacturer).
- Check lifting force of ball float (Pos. 24.16) by immersing the whole controller (Pos. 24) in
a water bath with the vent tube (Pos. 24.12) pointing upwards the spindle (Pos. 24.3) in a
horizontal position. When immersed in the water bath the ball (Pos. 24.16) must float to
the top. If the ball float (Pos. 24.16) sinks (i.e. goes under) the complete controller (Pos
24) should be replaced!
- The flat gasket (Pos. 17) and sealing ring (Pos. 11) should be replaced.
- Assemble in reverse order (refer to item 7.5).

Page 10 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps
7.2 Changing the installation position
(see Fig. 1- Fig. 2 page 4 and Fig. 3 page 8)
- Position body (Pos. 1) as desired, bearing in mind the direction of flow.
- Remove hood (Pos 16), then slacken hollow-core screw (Pos. 24.10) approximately 1/2
turn.
- Rotate controller (Pos. 24) 90º in the direction required.

ATTENTION !
The union for the pressure compensation line (Pos. 52) at the hood
(Pos. 16) must point up!

- Tighten hollow-core screw (Pos. 24.10) by holding against nozzle part (Pos. 24.11).
- Inspect and if necessary replace body seal (Pos. 17).
- Put on hood (Pos. 16) with the drain plug (Pos. 50) pointing diagonally down.
- Fit hexagonal nuts (Pos. 28) (see 7.5) and tighten crosswise.
- Reconnect pressure compensation pipe to the union for the pressure compensation line
(Pos. 52).

Fig. 5: Controller, cpl.

Rev. 0040805002 4608 Page 11

 Operating and installation instructions
CONA®S - Ball float steam traps
7.3 Options blow down valve / manual air vent valve
(refer to Fig. 1 page 4 and Fig. 6)

ATTENTION !
Escape of hot medium under pressure!
Observe item 2.2 !

Accumulated dirt and condensate can be removed from the

hood (Pos. 16) through the blow down valve by opening the
pressure screw (Pos. 46.1). When opening, hold against blow
down valve (Pos. 46).
Accumulating inert gases can also be discharged to the
environment with the manual air vent valve (Pos. 51) by
opening the pressure screw (Pos 51.1).
During operation it is imperative to observe general working
safety conditions and possibly fit devices to guard against
scalding/injury.
Note section 7.5 when installing and operating the option.

Fig. 6

7.4 Union for pressure compension line / external vent

(refer to Fig. 4 page 9)
It is possible to return the accumulating gases to the system
by connecting a pressure compensation line to the union
(Pos. 52).
Note section 7.5 when installing the option.

Pressure compensation pipe

Ermeto connection: external pipe diameter 8 mm
When delivered the Ermeto connection is sealed by a 12 mm
diameter stainless steel ball.
Remove this ball when installing the pressure compensation
pipe. Fig. 7

Page 12 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps
7.5 Tightening torques
(refer to Fig. 1 page 4 - Fig. 6 page 12)

Torque (Nm)
Pos. CONA S PN16
DN15-20 DN25 DN32-50
24 Controller 60 60 100
24.8 Hex. nut M4 / M4 / M6 5 5 10
50 Plug 50 50 50
27 Cheese head screw M10 / M12 / M16 15 25 50
51 Manual air vent valve 50 50 50
51.1 Pressure screw 30 30 30
46 Blow down valve 50 50 50
46.1 Pressure screw 30 30 30
52 Union for pressure compension line 50 50 50

Torque (Nm)
Pos. CONA S PN40
DN15-20 DN25 DN32-50
24 Controller 60 60 100
24.8 Hex. nut M4 / M6 5 5 10
28 Hex. nut M12 / M12 / M16 25 30 60
50 Plug 70 70 70
51 Manual air vent valve 70 70 70
51.1 Pressure screw 30 30 30
46 Blow down valve 70 70 70
46.1 Pressure screw 30 30 30
52 Union for pressure compension line 70 70 70

8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.

ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

If malfunctions cannot be eliminate with the help of the following table

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

Rev. 0040805002 4608 Page 13

 Operating and installation instructions
CONA®S - Ball float steam traps

9.0 Troubleshooting table

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

Fault Possible cause Corrective measures

No flow Installed in wrong flow direction Fit valve in direction of flow arrow.
Note installation position; refer to item
5.5.1!
Flange covers not removed Remove flange covers
Ball float (Pos. 24.16) defective Check lifting force; refer to item 7.1
Condensate cannot get to steam trap Note installation position;
due to bad pipeline routing. refer to item 7.4
Reduced flow Wrong installation position Correct installation position; refer to item
5.5.1! Correct installation position; refer
to item 7.2
Strainer clogged (Pos. 2) Clean strainer; refer to item 7.1
Piping system clogged Check piping system
Wrong controller size choosen Correct selection acc. to flow diagram
Changed upstream pressure or back Correct selection acc. to flow diagram
pressure operating conditions
Ball float (Pos. 24.16) prevented from Use pressure compensation line option;
swivelling, particularly in horizontal instal- refer to item 7.4
lation position
No closure, or internal Controller clogged Clean strainer and controller;
leakage refer to item 7.1
Controller worn out Change controller; refer to item 7.1
Controller incorrectly screwed into body Check seal face between body and con-
troller, tighten controller correctly; refer
to item 7.5
Controller operated above safe operating Observe operating limits as per data
pressure sheet, i.e. possibly select different con-
troller
External leakage Hood (Pos. 16) not properly tightened Tighten; refer to item 7.5
with hex. nut (Pos. 28) or cheese-head
screw (Pos. 27)
Flat gasket (Pos. 17) defective. Replace sealing;
see 7.1

Page 14 Rev. 0040805002 4608

 Operating and installation instructions
CONA®S - Ball float steam traps

10.0 Dismantling the valve or the body

ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.

11.0 Warranty / Guarantee

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

Technology for the Future.

GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: [email protected]

Rev. 0040805002 4608 Page 15

 Operating and installation instructions
CONA®S - Ball float steam traps

12.0 EC declaration of conformity

®
AWH ARMATUREN-
HALLE
WERK HALLE GMBH
a member of the ARI group

AWH Armaturenwerk Halle GmbH,

Turmstrasse 118, D-06110 Halle/Saale

EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC

Herewith we declare,

that according to the above mentioned Pressure Equipment Directive (PED) the below
listed products comply and have been approved according to Module B1+D through TÜV
Hannover/Sachsen Anhalt e.V. (BS-No. 0045), Saalfelder Strasse 33-34, 06116 Halle/
Saale.

Ball float steam traps

CONA® S

Series Nom. press. Material DN Certificate-No.

630 PN 40 0.7043 40-50 07 202 6111 Z 0016/1/E 02
630 PN 40 1.0460; 1.4541 40-100 07 202 6736 Z 0016/2/E 31;...32;...33;...34
630 Class 300 SA105; SA182F321 1 1/2“ - 4“ 0662/126/02

Applied standards:
DIN 3840
AD 2000-leaflet
ASME VIII/1

Halle/Saale, 06.04.2004

........................................................
(Dr. Urbanek, Managing director)

Rev. 0040805002 4608 Page 16

 2 3 4 5 6 7 8

A A
aut. condensate dra 1n-un 1t PN63
electronic-controlled

manual ball-valve G 1/2

(normally open)

adjustable T- f itt 1ng

B 110 B

G 1/2 male
connection for cc:-::c~~~~" --)
condensate inlet Lri;
min. sett1ng ~~mgle
of T- f i t t ng/1

[ [

G3/B dra1n outlet connection

79
80 O-R1ng 017 X 3 0119118 0.00

70 2 GE18ZLRED CF St 1039428 0.15

direct screw-connect 1on

D 60 Pr aStahlrohr nahtl P23ST2 2391 PraRo o1B.Ox2.0 0065640 0.08 D

so T-Stutzen T18LC F 0557429 0.39
union tee
40 2 Edelstahl Kugelhahn G 112, I G-1 G G 112, PN 70, PTFE seal 0359114 0.4 7
Ball valve stainless steel. G 112
30 GE18LRED OMD CF St 1039444 0.00
d 1rect screw-connect 1on
20 Gerader Einschraubstutzen St EGE18LRED CF 0557423 0.16
male stud connector
10 Bekomat 12 0079496 6.17
aut om. cond. drain
Pos. Stk. Benennung Werkstoff Abnahme D IN Abmessung/Bemerkung Art. Nr. Gew 1chi
pos. p1ece descr ipt 1on material 1nspect 1on d imens 1on/remark art. no. weight
E EN10204 [Kg I E
2 Ze 1chnung erg anzt 30.09.2015 T.Wegner
manual "by-pass" 1 0-R 1ng h inzugef ugt 19.02.2015 T.Wegner
G 1/2 ball-valve (normally closed) 0 11.12.2013 Bhs
incl. outlet connector for 018-pipe Index Anderung Dalum Name
PC 50 Dalum Name Werkstoff -0 aten Bez .:
Gez. 11.12.2013 Bhs Nr. Bez. 10 IN EN): NEUENHAUSER
Gepr.
Status
30.09.2015 T .Wegner

Fee igegeben
lf------=-~----c------:-----1
Schutzvecmeck nach
D 1N 1so 16016 beach ten!
Halbzeug-0 aten
Halbzeug
DIN- Norm
EN-Norm
Halbzeug-Nr.

( KOMPRESSORENBAU
D-49828 NEUENHAUS
TELEFON 105941) 604-0
TELEFAX (05941) 604-202
e-mail NK©neuenhauser .de
F Ma Sstab Art. Nr. 1077 445 F
c/w adjustable fitt1ngs BGR En t w ass erung 1nk l . Bypass Z. Nr. Zu_31671
aut. drain assembly incl. by-pass
dimensions might be vary because of fabrications tolerances 12 Index 2 Blatt -Nr. 1
m1t elektr. Kondensatable iter PN 63 Ersatz fur
1ncl. electr. condensate drain PN 63
Ersetzt durch
ZU_31671-0-2 2 3 4 5 6 7 8 A3
 Installations- und Betriebsanleitung deutsch

Instructions for installation and operation english

Instructions de montage et de service français

Installatie- en Gebruiksaanwijzing nederlands

BEKOMAT® 12 (BM12)
BEKOMAT® 12 CO (BM12CO)
BEKOMAT® 12 CO PN63 (BM12COPN63)

Sehr geehrter Kunde,

vielen Dank, dass Sie sich für den Kondensatableiter BEKOMAT entschieden haben. Bitte lesen Sie vor Montage und Inbe-
triebnahme des BEKOMAT diese Installations- und Betriebsanleitung aufmerksam und befolgen Sie unsere Hinweise. Nur
bei genauer Beachtung der beschriebenen Vorschriften und Hinweise ist die einwandfreie Funktion des BEKOMAT und damit
eine zuverlässige Kondensatableitung sichergestellt.

Dear Customer,
Thank you for deciding in favour of the condensate drain BEKOMAT. Please read the present instructions carefully before
installing your BEKOMAT unit and putting it into service. The perfect functioning of the condensate drain BEKOMAT - and thus
reliable condensate discharge - can only be guaranteed if the recommendations and conditions stated here are adhered to.

Cher client,
Vous venez d'acquérir un purgeur de condensat BEKOMAT et nous vous en félicitons. Nous vous recommandons de lire
attentivement ces instructions avant le montage et la mise en service du BEKOMAT et de suivre nos conseils. Car, seul le
respect scrupuleux des prescriptions et consignes données, peut garantir le parfait fonctionnement du BEKOMAT et une
purge fiable du condensat.

Geachte klant,
Wij danken u voor het aanschaffen van de kondensaatafvoer BEKOMAT. Wij verzoeken u voor installatie en ingebruikname
01-043

van de BEKOMAT eerst deze handleiding goed door te lezen. Alleen door het opvolgen van de voorschriften is een goede
werking van de BEKOMAT en daardoor een ongestoorde kondensaatafvoer gegarandeert.

BEKOMAT 12, 12 CO, 12 CO PN63 1

 Sicherheitshinweise

Bitte prüfen, ob diese Anleitung auch dem Gerätetyp entspricht.

Beachten Sie alle in dieser Bedienungsanleitung gegebenen Hinweise. Sie enthält grundlegende Informationen, die
bei Installation, Betrieb und Wartung zu beachten sind. Daher ist diese Bedienungsanleitung unbedingt vor Installation,
Inbetriebnahme und Wartung vom Monteur sowie vom zuständigen Betreiber/Fachpersonal zu lesen. Die Bedienungs-
anleitung muss jederzeit zugänglich am Einsatzort des BEKOMAT® 12 / 12 CO / 12 CO PN63 verfügbar sein.
Zusätzlich zu dieser Betriebsanleitung sind ggf. örtliche bzw. nationale Vorschriften zu beachten.
Stellen Sie sicher, dass der BEKOMAT® 12 / 12 CO / 12 CO PN63 nur innerhalb der zulässigen und auf dem Typen-
schild aufgeführten Grenzwerte betrieben wird. Es besteht sonst eine Gefährdung für Menschen und Material und es
können Funktions- und Betriebsstörungen auftreten.
Bei Unklarheiten oder Fragen zu dieser Installations- und Betriebsanleitung setzen Sie sich bitte mit BEKO TECHNO-
LOGIES GMBH in Verbindung.

Gefahr!
Druckluft!
Durch Kontakt mit schnell oder schlagartig entweichender Druckluft oder durch berstende und/oder nicht
gesicherte Anlagenteile besteht Gefahr schwerer Verletzungen oder Tod.

Maßnahmen:
• Max. Betriebsdruck nicht überschreiten (siehe Typenschild).
• Wartungsarbeiten nur im drucklosen Zustand durchführen.
• Nur druckfestes Installationsmaterial verwenden.
• Zulaufleitung fest verrohren. Ablaufleitung: kurzer, fixierter Druckschlauch an druckfestem Rohr.
• Verhindern Sie, dass Personen oder Gegenstände von Kondensat oder entweichender Druckluft getroffen werden können.

Gefahr!
Netzspannung!
Durch Kontakt mit Netzspannung führenden nicht isolierten Teilen besteht Gefahr eines elektrischen Schla-
ges mit Verletzung und Tod.

Maßnahmen:
• Bei elektrischer Installation alle geltenden Vorschriften einhalten (z.B. VDE 0100 / IEC 60364).
• Wartungsarbeiten nur im spannungsfreien Zustand durchführen.
• Alle elektrischen Arbeiten dürfen nur von befugtem Fachpersonal durchgeführt werden.

Weitere Sicherheitshinweise:
• Bei Installation und Betrieb sind ebenfalls die geltenden nationalen Bestimmungen und Sicherheitsvorschriften einzuhalten.
• Den BEKOMAT 12 nicht in explosionsgefährdeten Bereichen einsetzen.
• Bei den Zulaufverschraubungen sind übermäßige Anzugskräfte zu vermeiden. Das gilt insbesondere für konische Verschrau-
bungen.
• Der BEKOMAT 12 ist nur bei anliegender Spannung funktionstüchtig.
• Test-Taster nicht zur Dauerentwässerung nutzen.
• Nur Original-Ersatzteile verwenden. Nur so ist eine einwandfreie Funktion sichergestellt.

Zusatzhinweise:
• Bei Montage Schlüsselflächen am Zulauf (Schlüsselweite SW36) zum Gegenhalten benutzen.

2 BEKOMAT 12, 12 CO, 12 CO PN63

 Vorsicht!
Fehlfunktionen in der Anwendung!
Durch fehlerhafte Installation und mangelhafte Wartung kann es zu Fehlfunktionen am BEKOMAT kommen.
Nicht abgeleitetes Kondensat kann zu Schäden an Anlagen und in Fertigungsprozessen führen.

Maßnahmen:
• Eine funktionssichere Kondensatableitung optimiert direkt die Druckluftqualität.
• Zur Vermeidung von Schäden und Ausfällen bitte unbedingt beachten:
• genaues Einhalten der bestimmungsgemäßen Verwendung und der Betriebsparameter des BEKOMAT im Zusammen-
hang mit dem Einsatzfall (siehe dazu Kapitel „Bestimmungsgemäße Verwendung“)
• genaues Einhalten der Installations- und Betriebshinweise in dieser Anleitung
• regelmäßige Wartung und Kontrolle des BEKOMAT nach den Hinweisen in dieser Betriebsanleitung

Bestimmungsgemäße Verwendung

• Der BEKOMAT ist ein elektronisch-niveaugeregelter Kondensatableiter für Druckluftanlagen.

• Der Einsatz erfolgt innerhalb der zulässigen Betriebsparameter (siehe Technische Daten).
• Der BEKOMAT kann Kondensat unter Betriebsdruck nahezu ohne Druckluftverlust aus den Anlagenteilen ableiten.
• Der BEKOMAT benötigt zur Funktion eine Betriebsspannung und einen Betriebsdruck (siehe Technische Daten).
• Bei einem Einsatz in Anlagen mit erhöhten Anforderungen an die Druckluftqualität (Lebensmittelindustrie, Medizintechnik,
Laborausrüstungen, spezielle Prozesse usw.), muss der Betreiber über Maßnahmen zur Überwachung der Druckluftqua-
lität entscheiden. Diese beeinflussen die Sicherheit der nachfolgenden Prozesse und können Schäden an Menschen und
Anlagen vermeiden.
• Es ist Aufgabe des Betreibers, die genannten Bedingungen während der gesamten Betriebsdauer zu gewährleisten.
• Für den Einsatz in CO2-Anlagen muss ein BEKOMAT mit der Spezifikation CO (BEKOMAT .. CO) verwendet werden.
• Der BEKOMAT und die Kondensatzuleitung sind vor Frost zu schützen, da sonst die Funktion nicht gewährleistet ist.
BEKO bietet auch hierfür geeignete Produkte an.

Ausschluss vom Anwendungsbereich

• Der BEKOMAT kann als Kondensatableiter allein keine definierte Druckluftqualität garantieren, hierzu sind andere zusätz-
liche technische Einrichtungen notwendig.
• Der BEKOMAT 12 ist nicht für den Einsatz an Unterdruck oder atmosphärischen Umgebungsdruck führenden Anlagen
oder in Ex-Bereichen geeignet.
• Der BEKOMAT darf nicht dauerhafter direkter Sonnen- oder Wärmestrahlung ausgesetzt werden.
• Der BEKOMAT 12 darf nicht in Bereichen mit aggressiver Atmosphäre installiert und betrieben werden.

BEKOMAT 12, 12 CO, 12 CO PN63 3

 Safety instructions

Please check whether or not these instructions correspond to the device type!
Please adhere to all advice given in these operating instructions. They include basic information which needs to be
observed during installation, operation and maintenance. Therefore, it is vital for the technician and the responsible
operator /skilled personnel to read these operating instructions prior to installation, start-up and maintenance. The
operating instructions must be accessible at all times at the place of application of the BEKOMAT® 12 / 12 CO / 12 CO
PN63.
In addition to these operating instructions, local and national regulations need to be observed, if required.
Make sure that the BEKOMAT® 12 / 12 CO / 12 CO PN63 is operated only within the permissible limit values indicated
on the type plate. Any deviation involves a risk for persons and materials, and may result in malfunction and service
failures.
If you have any queries regarding these installation and operating instructions, please contact BEKO TECHNOLOGIES.

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping compressed air or
through bursting plant components or plant components which are not secured.

Measures:
• Do not exceed the maximum operating pressure (see type plate)!
• Only carry out service measures when the system is pressureless.
• Use pressure-resistant installation material only.
• The feed pipe must be tubed firmly. Discharge pipe: short, fixed pressure hose onto pressure-resistant pipe.
• Make sure that persons or objects cannot be hit by condensate or escaping compressed air.

Danger!
Supply voltage!
There is the risk of an electric shock involving injury or death when coming into contact with non-insulated
components carrying supply voltage.

Measures:
• During electric installations, all regulations in force need to be adhered to (e.g. VDE 0100 / IEC 60364).
• Service measures must only be undertaken when the system is deactivated!
• All types of electrical work must be carried out by authorised and qualified personnel only.

Further safety advice:

• For installation and operation, the national regulations and safety codes in force must also be adhered to.
• Do not use the BEKOMAT 12 in hazardous areas.
• Regarding the inlet screw joints, excessive tightening forces must be avoided. This applies in particular to conical screw
joints.
• The BEKOMAT 12 will only function when voltage is applied.
• Do not use the test button for permanent drainage!
• Only use genuine spare parts! This is imperative to ensure perfect functioning.

Additional advice:
• During installation, use the spanner flat at the feed pipe (width across flat 36) as a back rest.

4 BEKOMAT 12, 12 CO, 12 CO PN63

 Caution!
Malfunctions in the application!
Through incorrect installation and insufficient maintenance, the BEKOMAT can malfunction. Condensate
which is not discharged can lead to damage to plants and in manufacturing processes.

Measures:
• Fail-safe condensate discharge directly optimises the compressed-air quality.
• To prevent damage and failures, it is imperative
• To comply with the provisions regarding proper use and with the operating parameters of the BEKOMAT in connection
with the case of application (see chapter "Proper use").
• To strictly adhere to the installation and operating advice in these instructions.
• To maintain and check the BEKOMAT at regular intervals in accordance with the advice in these operating instructions.

Proper use
• The BEKOMAT is an electronically level-controlled condensate drain for compressed-air plants.
• It is employed within the permissible operating parameters (see "Technical data").
• The BEKOMAT is able to drain condensate under operating pressure from the plant components virtually without com-
pressed-air losses.
• For its function, the BEKOMAT 12 requires an operating voltage and an operating pressure (see "Technical data").
• As far as the employment in plants with increased demands on the compressed-air quality is concerned (food industry, medi-
cal technology, laboratory equipment, special processes etc.), the operator must decide on measures for the monitoring of
the compressed-air quality. These have an effect on the safety of the subsequent processes and may prevent damage to
persons and plants.
• It is the task of the operator to ensure that the indicated conditions are met during the entire operating time.
• For the employment in CO2 plants, a BEKOMAT with a CO specification (BEKOMAT ... CO) must be used.
• The BEKOMAT and the condensate supply line need to be protected against frost, as otherwise the function cannot be guar-
anteed. BEKO also offers suitable products for this purpose.
• The additional control allows the user to externally actuate the BEKOMAT valve with a 24 V control voltage (relay K1), and to
monitor the valve switching cycles via a potential-free contact (relay K2).

Exclusion from the field of application

• The BEKOMAT as a condensate drain alone cannot guarantee a defined compressed-air quality, for this purpose, other ad-
ditional technical devices are required.
• BEKOMAT 12 is not suitable for use in plants carrying vacuum or atmospheric ambient pressure or in hazardous areas.
• The BEKOMAT must not be exposed to permanent direct solar or thermal radiation.
• BEKOMAT 12 must not be installed and operated in areas with an aggressive atmosphere.

BEKOMAT 12, 12 CO, 12 CO PN63 5

 Consignes de sécurité

Vérifiez que cette notice corresponde bien au modèle d'appareil en votre possession.
Respectez toutes les consignes données dans ce mode d'emploi. Il contient des informations fondamentales, à res-
pecter lors de l'installation, de l'utilisation et de la maintenance. C'est pourquoi, il est impératif que ce mode d'emploi
soit lu avant l'installation, la mise en service et la maintenance, par l'installateur ainsi que par l'exploitant et le person-
nel qualifié.
Le mode d'emploi doit être disponible et accessible à tout moment sur le lieu d'utilisation du BEKOMAT® 12 / 12 CO /
12 CO PN63.
En plus de ce mode d'emploi, il faut respecter les éventuelles prescriptions locales ou nationales.
Assurez-vous que le BEKOMAT® 12 / 12 CO / 12 CO PN63 ne soit utilisé qu'au sein des valeurs limites admissibles
et mentionnées sur la plaque signalétique. Dans le cas contraire, il peut présenter un risque pour les personnes et le
matériel, voire nuire au bon fonctionnement de l'installation ou générer des perturbations.
Si certains points ne sont pas clairs ou si vous avez des questions au sujet de ces instructions de montage et de ser-
vice, n'hésitez pas à contacter la société BEKO TECHNOLOGIES.

Danger !
Air comprimé !
Tout contact avec de l'air comprimé s'échappant rapidement ou de façon brutale ou tout contact avec des
parties de l'installation présentant un risque d'éclatement peut causer de graves blessures ou entraîner la mort.

Mesures préventives :
• Ne pas dépasser la pression de service maximale (voir plaque signalétique).
• Dépressuriser le purgeur avant toute intervention d'entretien ou de maintenance.
• N'utiliser que du matériel d'installation résistant à la pression.
• La conduite d'amenée doit toujours être réalisée en tuyauterie rigide et fixe. Conduite d'évacuation : flexible de faible lon-
gueur, fixé et relié à une tuyauterie, tous deux résistant à la pression.
• Veillez à ce qu'aucune personne ni objet ne risque d'être touché par le condensat ou l'air comprimé qui s'échappe.

Danger !
Tension électrique !
Tout contact avec des éléments non isolés et sous tension présente un risque de choc électrique pouvant
provoquer des blessures ou entraîner la mort.

Mesures préventives :
• Lors de la réalisation de l'installation électrique, respecter toutes les prescriptions en vigueur (p. ex. VDE 0100 / IEC 60364).
• Avant toute intervention d'entretien ou de maintenance, mettre le purgeur HORS TENSION.
• Toute intervention électrique doit être réalisée exclusivement par un personnel qualifié et habilité.

Autres consignes de sécurité :

• Lors de l'installation et de l'utilisation, il faut également respecter les directives et consignes de sécurité en vigueur dans le
pays en question.
• Ne pas utiliser le BEKOMAT 12 dans les atmosphères explosibles.
• Éviter les serrages trop importants au niveau des raccords de la conduite d'amenée Ceci est valable en particulier pour les
raccords à filetage conique.
• Le BEKOMAT 12 n'est opérationnel que s'il est sous tension (alimentation électrique assurée).
• Ne pas utiliser le bouton Test pour l'évacuation permanente du condensat.
• Utiliser exclusivement des pièces de rechange d'origine. Seul le respect scrupuleux des consignes données peut garantir le
parfait fonctionnement de l'appareil.

Consignes supplémentaires :
• Lors du montage, utiliser le méplat pour clé au niveau de l'arrivée (36 mm) pour maintenir le purgeur pendant le serrage.

6 BEKOMAT 12, 12 CO, 12 CO PN63

 Prudence !
Dysfonctionnements au niveau de l'utilisation !
En cas d'installation incorrecte et de maintenance insuffisante, des dysfonctionnements peuvent apparaître
au niveau du BEKOMAT.
Tout condensat non évacué risque d'endommager les installations et de porter atteinte aux processus de
fabrication.

Mesures préventives :
• Le bon fonctionnement de la purge des condensats permet une optimisation directe de la qualité de l'air comprimé.
• Pour éviter tout endommagement et tout arrêt de production, il est impératif de respecter les consignes suivantes :
• Respecter scrupuleusement les instructions pour une utilisation conforme à l’usage prévu et les paramètres de fonction-
nement du BEKOMAT dans le contexte de son utilisation (consulter à cet effet le chapitre „Utilisation conforme à l’usage
prévu“).
• Respecter scrupuleusement toutes les instructions d'installation et d'utilisation communiquées dans cette notice.
• Respecter scrupuleusement la périodicité de maintenance et de contrôle du BEKOMAT selon les indications de ce ma-
nuel d'utilisation.

Utilisation conforme à l'emploi prévu

• Le BEKOMAT est un purgeur de condensat à régulation électronique de niveau pour les installations de production et distri-
bution d'air comprimé.
• L'utilisation s'effectue dans le respect des paramètres de fonctionnement admissibles (voir caractéristiques techniques).
• Le BEKOMAT permet d'évacuer le condensat du réseau de distribution sous pression (pression de service) et ce, pratique-
ment sans perte de charge.
• Pour son fonctionnement, le BEKOMAT requiert une tension d'alimentation électrique et une pression de service (voir carac-
téristiques techniques).
• Lors d'une utilisation dans des installations soumises à des exigences plus poussées quant à la qualité de l'air comprimé
(industrie alimentaire, techniques médicales, équipements de laboratoires, processus spéciaux, etc.), l'exploitant est tenu
de prendre des mesures pour la surveillance de la qualité de l'air comprimé. Ces mesures ont une influence directe sur la
sécurité des processus en aval et permettent ainsi d'éviter les dommages corporels et l'endommagement des installations.
• Il incombe à l'exploitant d'assurer les conditions mentionnées pendant toute la durée de service.
• Pour les installations de CO2, il faut impérativement utiliser un BEKOMAT en version CO (BEKOMAT .. CO).
• Le BEKOMAT et la conduite d'amenée du condensat doivent être protégés contre le gel, sinon le fonctionnement n'est pas
assuré. BEKO propose également des produits adéquats à cet effet.
• La commande supplémentaire permet à l'utilisateur de réaliser une commande externe pour l'électrovanne du BEKOMAT à
l'aide une tension électrique de commande de 24 V (Relais K1 ainsi que la surveillance des cycles de manœuvre de l'élec-
trovanne par l'intermédiaire d'un contact sans potentiel (relais K2).

Exclusion du domaine d'application

• En tant que purgeur de condensat, le BEKOMAT ne peut pas garantir à lui seul une qualité d'air comprimé définie ; pour ce
faire, il faut d'autres équipements techniques en plus.
• Le BEKOMAT 12 ne convient pas pour l'utilisation sur des installations sous vide ou fonctionnant à la pression atmosphé-
rique ambiante, ni pour l'utilisation dans les atmosphères explosibles.
• Le BEKOMAT ne doit pas être exposé en permanence au rayonnement direct du soleil ou à un rayonnement thermique.
• Le BEKOMAT 12 ne doit pas être installé ni utilisé dans les domaines exposés à une atmosphère agressive.

BEKOMAT 12, 12 CO, 12 CO PN63 7

 Veiligheidsinstructies

Controleer of deze handleiding ook overeenkomt met het apparaattype.

Neem alle instructies in acht die in deze gebruiksaanwijzing worden gegeven. Zij omvat essentiële informatie die in
acht moet worden genomen bij de installatie, het gebruik en het onderhoud. Daarom moet deze gebruiksaanwijzing
vóór de installatie, de ingebruikname en het onderhoud absoluut gelezen worden door de monteur, de verantwoorde-
lijke exploitant of het vakkundig personeel.
De gebruiksaanwijzing moet op elk gewenst moment toegankelijk beschikbaar zijn op de plaats waar de BEKOMAT®
12 / 12 CO / 12 CO PN63 wordt gebruikt.
Voorts moeten bij deze gebruiksaanwijzing eventueel lokale resp. nationale voorschriften in acht worden genomen.
Controleer of de BEKOMAT® 12 / 12 CO / 12 CO PN63 uitsluitend wordt gebruikt binnen de toegestane grenswaarden
die ook zijn aangegeven op de instructieplaat. Zo niet bestaat er gevaar voor personen en materiaal en kunnen er
functie- en bedrijfsstoringen optreden.
Neem contact op met BEKO TECHNOLOGIES GMBH als er onduidelijkheden of vragen zijn over deze installatie- en
gebruikershandleiding.

Gevaar!
Perslucht!
Contact met perslucht die snel of abrupt ontsnapt of wegspringende en/of niet beveiligde delen van de ins
tallatie leveren gevaar op met zwaar letsel of dood tot gevolg.

Maatregelen:
• Overschrijd de maximale bedrijfsdruk niet (zie instructieplaat).
• Verricht onderhoudswerkzaamheden uitsluitend in drukloze toestand.
• Gebruik uitsluitend drukbestendig installatiemateriaal.
• Verbind de toevoerleiding vast met het buizensysteem. Afvoerleiding: bevestig een korte hogedrukslang aan de drukbesten-
dige buis.
• Voorkom dat personen of voorwerpen geraakt kunnen komen door condensaat of ontsnappende perslucht.

Gevaar!
Netspanning!
Contact met niet-geïsoleerde delen die de netspanning voeren, levert gevaar op door elektrische schok met
letsel en dood tot gevolg.

Maatregelen:
• Volg bij elektrische installatie alle geldende voorschriften op (bijv. VDE 0100 / IEC 60364).
• Verricht onderhoudswerkzaamheden uitsluitend in spanningsvrije toestand.
• Alle elektrische werkzaamheden mogen uitsluitend worden uitgevoerd door bevoegd vakpersoneel.

Overige veiligheidsinstructies:
• Bij installatie en gebruik moeten tevens de geldende nationale bepalingen en veiligheidsvoorschriften in acht worden geno-
men.
• Gebruik de BEKOMAT 12 niet in explosiegevaarlijke zones.
• Vermijd overmatig aantrekken van de schroefverbindingen aan de toevoer. Dat geldt in het bijzonder voor conische schroef-
verbindingen.
• De BEKOMAT 12 kan alleen functioneren bij opgebrachte spanning.
• Gebruik de testknop niet voor continue drainage.
• Gebruik alleen originele reserveonderdelen. Alleen zo kan een foutloze werking worden gegarandeerd.

Aanvullende instructies:
• Gebruik bij montage de sleuteloppervlakken op de toevoer (sleutelbreedte SW36) om de Bekomat tegen te houden.

8 BEKOMAT 12, 12 CO, 12 CO PN63

 Let op!
Storingen tijdens het gebruik!
Er kunnen storingen aan de BEKOMAT ontstaan als gevolg van een foutieve installatie en gebrekkig onder-
houd.
Niet afgevoerd condensaat kan schade veroorzaken aan installaties en in productieprocessen.

Maatregelen:
• Een veilig functionerende condensaatafvoer optimaliseert direct de persluchtkwaliteit.
• Neem het volgende absoluut in acht om schade en uitval te voorkomen:
• Correct opvolgen van de instructies voor doelmatig gebruik en van de bedrijfsparameters van de BEKOMAT afhankelijk
van de gebruikssituatie (zie hiervoor hoofdstuk "Doelmatig gebruik")
• Correct opvolgen van de installatie- en bedrijfsinstructies in deze handleiding
• Regelmatig onderhoud en controle van de BEKOMAT volgens de instructies in deze gebruiksaanwijzing

Doelmatig gebruik
• De BEKOMAT is een elektronisch niveaugeregelde condensaatafvoer voor persluchtinstallaties.
• Het gebruik vindt plaats binnen de toegestane bedrijfsparameters (zie technische gegevens).
• De BEKOMAT kan condensaat onder bedrijfsdruk praktisch zonder persluchtverlies uit de installatie afvoeren.
• Der BEKOMAT heeft voor het functioneren een bepaalde bedrijfsspanning en bedrijfsdruk nodig (zie technische gegevens).
• Bij een gebruik in installaties met hogere eisen aan de persluchtkwaliteit (voedingsmiddelenindustrie, medische techniek,
laboratoriumuitrustingen, speciale processen enz.) moet de exploitant maatregelen treffen voor het bewaken van de pers-
luchtkwaliteit. Deze hebben een invloed op de veiligheid van de nakomende processen en kunnen schade aan personen en
installaties voorkomen.
• Het is de taak van de exploitant om de genoemde voorwaarden tijdens de totale bedrijfsduur te waarborgen.
• Voor toepassing in CO2-installaties moet een BEKOMAT met de specificatie CO (BEKOMAT .. CO) worden gebruikt.
• Der BEKOMAT en de condensaatafvoer moeten beschermd worden tegen vorst omdat de werking anders niet gewaarborgd is.
BEKO biedt ook hiervoor geschikte producten aan.
• Met de extra besturingseenheid kan de gebruiker de BEKOMAT-klep met een 24 V-stuurspanning (relais K1) extern bedienen
alsook de schakelingen van de klep door middel van een potentiaalvrij contact (relais K2) bewaken.

Uitsluiting van toepassingsgebied

• De BEKOMAT kan als condensaatafvoer alleen geen gedefineerde persluchtkwaliteit garanderen. Hiervoor zijn andere aan-
vullende, technische installaties noodzakelijk.
• De BEKOMAT 12 is niet geschikt voor het gebruik bij installaties met onderdruk of atmosferische omgevingsdruk of in ex-
zones.
• De BEKOMAT mag niet continu worden blootgesteld aan direct zonlicht of warmtestraling.
• De BEKOMAT 12 mag niet worden geïnstalleerd en gebruikt in ruimtes met agressieve atmosfeer.

BEKOMAT 12, 12 CO, 12 CO PN63 9

 Technische Daten • Technical data
Caractéristiques • Gegevens

Dieses Produkt wurde getestet nach den Anforderungen der CAN/CSA-C22.2 Nr. 61010-1, zweite
Auflage, unter Einbeziehung der Ergänzung 1 oder einer späteren Version der gleichen Norm, unter
Berücksichtigung des gleichen Niveaus an Testanforderungen.
This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition,
including Amendment 1, or a later version of the same standard incorporation the same level of
testing requirements.
Ce produit a été testé selon les exigences de la norme CAN/CSA-C22.2 n° 61010-1, deuxième
édition, en tenant compte du complément 1 ou d'une version plus récente de la même norme, en
appliquant le même niveau d'exigences en matière de tests.
Dit product is getest volgens de vereisten van CAN/CSA-C22.2 nr. 61010-1, tweede uitgave, inclusief
aanvulling 1 of een latere versie van dezelfde norm, rekening houdend met hetzelfde niveau van
testvereisten.

BEKOMAT 12 12 CO 12 CO PN63

min./max. Betriebsdruck
operating pressure, min/max
0,8...16 bar 1,2...63 bar
Pression de service min/max
Min./max. bedrijfsdruk
min./max. Temperatur
min/max temperature
+1 ... +60 °C
Température min/max
Min./max. temperatuur
Kondensatzulauf
Condensate feed
G½
Entrée du condensat
Kondensaatinvoer
Kondensatablauf (Schlauch)
Condensate discharge (hose) G 3/8-A
G 3/8" - i
Sortie du condensat (flexible) (di=10-13mm)
Kondensaatafvoer (slang)
Kondensat ölhaltig ölhaltig + ölfrei
condensate oil-contaminated oil-contaminated + oil-free
Condensat huileux huileux + non huileux
Kondensaat oliehoudend oliehoudend + olievrij
Gehäuse Aluminium Aluminium, hartcoatiert
housing Aluminium Aluminium, hard-coated
Corps Aluminium Aluminium, avec revêtement dur
Behuizing Aluminium Aluminium, hardgecoat
Gewicht (leer)
weight (empty)
0,8 kg 0,9 kg
Poids (à vide)
Gewicht (leeg)

Max. Leistung für Klimazone Blau – siehe auch Kapitel „Klimazone und Leistungsdaten“
Max. performance for the blue climatic zone – see also Chapter "Climatic zone and performance data".
Capacité max. pour la zone climatique Bleu – voir aussi chapitre „Zones climatiques et Capacités“
Max. capaciteit voor klimaatzone blauw - zie ook het hoofdstuk "Klimaatzone en capaciteitsgegevens"

max. Kompressorleistung
peak compressor performance
6,5 m³/min
Capacité maximale du compresseur
Max. compressorcapaciteit
max. Kältetrocknerleistung (nur mit Vorabscheidung)
peak refrigeration dryer performance (only with pre-separation)
13 m³/min
Capacité max. du sécheur frigo (seules avec pré-separation)
Max. koeldrogercapaciteit (allen met voorafscheiding)
max. Filterleistung (hinter Trockner)
peak filter performance (behind dryer)
65 m³/min
Capacité maximale filtre (derriere sécheur)
Max. filtercapaciteit (achter koeldroger)
10 BEKOMAT 12, 12 CO, 12 CO PN63
 Elektrische Daten • Electrical data
Caractéristiques electrique • Elektrische gegevens

Betriebsspannung
230 / 115 / ... / 24 VAC ± 10%, 50 ... 60 Hz / 24 VDC ± 10%
Supply voltage
siehe Typenschild / see type plate
Tension d'alimentation
voir plaque signalétique / zie instructieplaat
Bedrijfsspanning
Leistungsaufnahme
Power input
P < 8,0 VA (W)
Consommation
Opgenomen vermogen
Absicherung empfohlen AC: 1 A träge / vorgeschrieben DC: 1 A träge
Fuse protection recommanded AC: 1 A slow / stipulated DC: 1 A slow
Fusibles recomm. AC : 1 A fusion lente / prescrit DC : 1 A fusion lente
Zekering aanbevolen AC: 1 A traag / specificatie DC: 1 A traag
empfohlener Kabelmanteldurchmesser
recommanded cable jacket diameter
ø 5,8 ... 8,5 mm (0.23" ... 0.34")
diamètre recommandé pour la gaine du câble
anbevolen kabeldoorsnede
empfohlener Aderquerschnitt (Netzanschluss)
recommended wire cross-section
3 x 0,75 ... 1,5 mm² (0.03 ... 0.06 inches squared)
Section recommandée pour les conducteurs (alimentation secteur)
Aanbevolen draaddoorsnede (netaansluiting)
empfohlenes Absetzen des Kabelmantels
recommended stripping of cable jacket
PE: ca. 60 mm L/N: ca. 50 mm
Longueur recommandée pour le dénudage de la gaine du câble
Aanbevolen strippen van de kabelmantel
empfohlene Abisolierlänge
recommended wire stripping
~ 6 mm (~ 0.24 inch)
Longueur recommandée pour le dénudage
Aanbevolen isolatielengte
Anschlussdaten des potenzialfreien Kontaktes
Last schalten *)
Connection data of the potential-free contact
Switch to load *) AC: max. 250 V / 1 A
Caractéristiques de raccordement du contact sans potentiel DC: max. 30 V / 1 A
Commuter une charge *)
Aansluitgegevens van het potentiaalvrije contact
Last schakelen *)

Anschlussdaten des potenzialfreien Kontaktes

Kleinsignel schalten *)
Connection data of the potential-free contact
Switch to low signal *)
min. 5 VDC / 10 mA
Caractéristiques de raccordement du contact sans potentiel
Commuter un petit signal *)
Aansluitgegevens van het potentiaalvrije contact
Laag signaal schakelen *)
Schutzart
Protection class
IP 65
Degré de protection
Beschermingsklasse

VAC = V alternating current (Wechselspannung) / VDC = V direct current (Gleichspannung)

*) das Schalten von Lasten führt dazu, dass die Eigenschaften des Kontaktes für das Schalten von Kleinsignalen nicht mehr
geeignet sind.
VAC = V alternating current / VDC = V direct current
*) The switching of loads has the result that the properties of the contact are no longer suitable for the switching of low signals.
VAC = V alternating current (Tension alternative) / VDC = V direct current (Tension continue)
*) La commutation de charges a pour conséquence que les propriétés du contact ne conviennent plus pour la commutation
de petits signaux.
VAC = V alternating current (wisselstroom) / VDC = V direct current (gelijkstroom)
*) het schakelen van lasten heeft als gevolg dat de eigenschappen van het contact niet meer geschikt zijn voor het schakelen
van lage signalen.
BEKOMAT 12, 12 CO, 12 CO PN63 11
 Abmessungen • Dimensions • Dimensions • Afmetingen

BEKOMAT 12
BEKOMAT 12 CO

BEKOMAT 12 CO PN63

12 BEKOMAT 12, 12 CO, 12 CO PN63

 Klimazonen • Climatic zone • Zones climatiques • Klimaatzone

Klimazone Max. Kompressorleistung Max. Trocknerleistung Max. Filterleistung

Climatic zone Peak compressor performance Peak dryer performance Peak filter performance
Zone climatique Capacité max. du compresseur Capacité max. du sécheur Capacité max. du filtre
Klimaatzone Max. compressorcapaciteit Max. koeldrogercapaciteit Max. filtercapaciteit

m³/min. m³/min. m³/min.

grün/green/vert/groen 8,0 16,0 80,0
blau/blue/bleu/blauw 6,5 13,0 65,0
rot/red/rouge/rood 4,0 8,0 40,0

Die angebenen Leistungsdaten beziehen sich auf gemäßigtes Klima mit Gültigkeit für Europa, weite Teile Süd-Ost-Asiens,
Nord- und Südafrika, Teile Nord- und Südamerikas (Klimazone: Blau).
Für trockenes und/oder kühles Klima (Klimazone: Grün) gilt folgender Faktor:
Leistung in Klimazone “Blau” ca. x 1,2
Für warmes und/oder feuchtes Klima (Tropen; Klimazone: Rot) gilt folgender Faktor:
Leistung in Klimazone “Blau” ca. x 0,7

The compressor capacity figures relate to mild climate valid for Europe, large parts of South-East Asia, Nothern Africa, parts
of North- and South America (climate zone: Blue)
For dry and/or cold climate (climate zone: Green),
multiply the Blue zone figure with the following correction factor: approx. 1.2
For warm and/or wet climate (climate zone: Red),
multiply the Blue zone figure with the following correction factor: approx. 0.7

Les capacités indiquées se rapportent à un climat tempéré, valable pour l‘Europe, certaines parties du Sud-Est asiatique,
l‘Afrique du Nord et du Sud, certaines parties de l‘Amérique du Nord et du Sud (zone climatique: bleu).
Pour un climat sec et/ou frais (zone climatique: vert), il convient d‘appliquer le facteur suivant :
Capacité en zone climatique “bleu” environ x 1,2
Pour un climat chaud et/ou humide (zones tropicales; zone climatique: rouge), il convient d‘appliquer le facteur suivant:
Capacité en zone climatique “bleu” environ x 0,7

De aangegeven capaciteitsgegevens hebben betrekking op een gematigd klimaat en zijn geldig voor Europa, grote delen van
Zuidoost-Azië, Noord- en Zuid-Afrika, delen van Noord- en Zuid-Amerika (klimaatzone: blauw).
Voor droog en/of koel klimaat (klimaatzone: groen) geldt de volgende factor:
vermogen in klimaatzone blauw ca. x 1,2
Voor warm en/of vochtig klimaat (de tropen; klimaatzone: rood) geldt de volgende factor:
vermogen in klimaatzone blauw ca. x 0,7

BEKOMAT 12, 12 CO, 12 CO PN63 13

 Funktion • Function
deutsch
Fonctionnement • Functiebeschrijving

Das Kondensat strömt über die Zulauf-

leitung (1) in den BEKOMAT und sam-
melt sich im Gehäuse (2). Ein kapazitiv
arbeitender Sensor (3) erfaßt permanent
den Füllstand und gibt ein Signal an die
1
elektronische Steuerung sobald sich der
4 Behälter gefüllt hat. Das Vorsteuerventil
(4) wird betätigt und die Membrane (5)
öffnet zur Kondensatausschleusung die
Ablaufleitung (6).
Ist der BEKOMAT geleert, wird die
Ablaufleitung rechtzeitig wieder dicht
verschlossen, bevor unnötige Druckluft-
2 3 5 6 verluste entstehen können.

Betriebsbereitschaft
1 Spannung liegt an

Ableitvorgang
2 Ablaufleitung ist geöffnet

Störung
1 2 3 Alarmmodus ist aktiviert

Test
4 manuelle Entwässerung/Alarm

Der Test-Taster dient zur Funktionskon-

trolle.
Betätigung Wirkung

3 4 ca. 2 sek. manuelle Entwässerung

> 1 min Alarmmodus

Schaltfolge des Ventils im Alarmmodus Stellt der Mikrocontroller eine Betriebsstö-

Switching sequence of valve in alarm mode rung fest, wird der Alarmmodus ausgelöst.
Séquence d'activation de la vanne en mode Alarme Die Schaltfolge des Ventils (siehe Bild)
Schakelvolgorde van het ventiel tijdens alarmfase dauert so lange an, bis die Ursache der
Störung behoben ist (selbsttätig oder
durch Wartung). Die rote LED blinkt
während der Alarmfunktion.
Mögliche Störungsursachern sind z.B.:
• Fehler in der Installation
• Unterschreiten des Minimaldruckes
• zu hoher Kondensatanfall (Überlast)
• verstopfte/gesperrte Ablaufleitung
• extreme Schmutzpartikelmenge
• eingefrorene Rohrleitungen
Ist die Störung nicht innerhalb der ersten
Minute behoben, wird eine Störmeldung
Alarmmeldung über potentialfreien Kontakt ausgelöst (siehe Bild), die als poten-
Alarm signal via potential-free contact tialfreies Signal über das Alarmrelais
Signal d'alarme délivré sur le contact sans potentiel abgegriffen wer den kann.
Alarmmelding via het potentiaalvrij contact

14 BEKOMAT 12, 12 CO, 12 CO PN63

 english français nederlands

The condensate flows through the feed Amené dans le BEKOMAT par la conduite Het kondensaat stroomt door de toevoer-
line (1) into the BEKOMAT unit and ac- d'arrivée (1), le condensat est collecté leiding (1) in de BEKOMAT en verzamelt
cumulates in the container (2). A capaci- dans le réservoir (2). Une sonde capacitive zich in het reservoir (2). De capacitieve
tive sensor (3) continuously registers the (3) surveille en permanence le niveau sensor (3) registreert permanent het
liquid level and passes a signal to the de remplissage et envoie un signal à la kondensaatniveau en geeft een signaal
electronic control as soon as the con- commande électronique dès que le réser- aan de elektronica, zodra het reservoir
tainer is filled. The pilot valve (4) is then voir est rempli. L'électrovanne pilote (4) gevuld is. De ventieleenheid (4) treedt
activated and the diaphragm (5) opens est activée et la membrane (5) ouvre la hierdoor in werking en het membraan
the outlet line (6) for discharging the conduite d'évacuation (6) pour l'éclusage (5) wordt omhoog gedrukt. Het konden-
condensate. du condensat. saat kan hierdoor in de afvoerleiding (6)
stromen.
When the BEKOMAT unit has been Dès que le BEKOMAT est vide, la conduite
emptied, the outlet line is closed again d'évacuation est à nouveau refermée avec Als het reservoir van de BEKOMAT ge-
quickly and tightly without wasting com- une parfaite étanchéité, avant même que leegd is, wordt de afvoer weer gesloten,
pressed air. l'air comprimé ne puisse s'échapper. voordat er onnodig verlies van dure
perslucht kan plaats vinden.

Ready for operation Prêt à fonctionner Bedrijfsklaar, de BEKOMAT

1 Voltage is being applied
1 Tension d'alimentation présente
1 staat onder spanning

Discharge procedure Phase de purge Afvoerproces

2 Outlet line is open
2 Conduite d'évacuation ouverte
2 De afvoerleiding is geopend

Malfunction Dysfonctionnement Storing

3 Alarm mode is activated
3 Mode Alarme activé
3 De alarmfase is geactiveerd

Test Test Test

4 Manual drainage/alarm 4 Purge manuelle/Alarme 4 Handmatige afvoer/alarm

The test button is used for checking La touche Test sert à tester le fonction- De testschakelaar dient ter functiecon-
correct functioning. nement. trole.
Pressing Effect Action Effet Activiteit Werking
approx. 2 sec Manual drainage environ 2 sec Purge manuelle ca. 2 sec handmatige afvoer
> 1 min Alarm mode > 1 min Mode Alarme > 1 min alarmfase

When the microcontroller registers a Lorsque le microcontrôleur détecte une Indien de microprocessor een storing
malfunction, the device will automatically anomalie, il active le mode alarme. La vaststelt, wordt de alarmfase in werking
change to the alarm mode. The switching séquence d'activation de la vanne (voir gesteld. De schakelvolgorde van het ven-
sequence of the valve (see illustration) figure) persiste jusqu'à ce que le problème tiel (zie afbeelding) duurt voort, zo lang tot
continues until the fault is cleared (auto- soit résolu (automatiquement ou par inter- de storing is opgelost (zelfstandig of door
matically or through maintenance). The vention de maintenance). La LED rouge onderhoud). Gedurende de alarmfase
red LED flashes as long as the device clignote pendant la fonction d'alarme. knippert de rode LED.
is in the alarm mode.
Causes de dysfonctionnement possi- Mogelijke storingsoorzaken zijn b.v.:
Malfunctioning could be caused by, e.g.: bles: • Een installatiefout
• Mistakes during installation • Défaut au niveau de l'installation • De werkdruk ligt onder de min. druk
• Dropping below the necessary mini- • Pression minimale non atteinte • Overbelasting (te veel kondensaat)
mum pressure • Trop de condensat (surcharge) • Verstopte/afgesloten afvoerleiding
• Excessive condensate quantities (over- • Ecoulement bouché ou obturé • Extreme hoeveelheden vuildeeltjes
loading) • Importantes quantités d'impuretés • Bevroren leidingen
• Blocked/shut off outlet line • Conduites gelées
• Extreme amount of dirt particles
Si la panne n'est pas résolue en l'espace Indien de storing niet binnen een mi-
• Frozen piping
d'une minute, un signal d'alarme est émis nuut is verholpen, wordt een storing
If the fault is not cleared within the first (voir figure). Un signal sans potentiel est gemeld (zie afbeelding). Deze kan als
minute, a fault signal is triggered (see délivré par le relais d'alarme. potentiaalvrij signaal via het alarmrelais
illustration) which can be picked off as a aan een centraal meldpunt worden
potential-free signal via the alarm relay. doorgegeven.

BEKOMAT 12, 12 CO, 12 CO PN63 15

 Installation

Gefahr!
Druckluft!
Durch Kontakt mit schnell oder schlagartig entweichender Druckluft oder durch berstende und/oder nicht
gesicherte Anlagenteile besteht Gefahr schwerer Verletzungen oder Tod.

Maßnahmen:
• Max. Betriebsdruck nicht überschreiten (siehe Typenschild).
• Wartungsarbeiten nur im drucklosen Zustand durchführen.
• Nur druckfestes Installationsmaterial verwenden.
• Zulaufleitung fest verrohren. Ablaufleitung: kurzer, fixierter Druckschlauch an druckfestem Rohr.
• Verhindern Sie, dass Personen oder Gegenstände von Kondensat oder entweichender Druckluft getroffen werden können.

Vorsicht!
Fehlfunktionen in der Anwendung!
Durch fehlerhafte Installation und mangelhafte Wartung kann es zu Fehlfunktionen am BEKOMAT kommen.
Nicht abgeleitetes Kondensat kann zu Schäden an Anlagen und in Fertigungsprozessen führen.

Maßnahmen:
• Eine funktionssichere Kondensatableitung optimiert direkt die Druckluftqualität.
• Zur Vermeidung von Schäden und Ausfällen bitte unbedingt beachten:
• genaues Einhalten der bestimmungsgemäßen Verwendung und der Betriebsparameter des BEKOMAT im Zusammen-
hang mit dem Einsatzfall (siehe dazu Kapitel „Bestimmungsgemäße Verwendung“)
• genaues Einhalten der Installations- und Betriebshinweise in dieser Anleitung
• regelmäßige Wartung und Kontrolle des BEKOMAT nach den Hinweisen in dieser Betriebsanleitung

Hinweis:

Beachten Sie unbedingt alle aufgeführten Gefahren- und Warnhinweise.

Beachten Sie auch alle Vorschriften und Hinweise des Arbeits- und Brandschutzes am jeweiligen Installationsort.
Verwenden Sie grundsätzlich nur geeignetes und passendes Werkzeug und Material in ordnungsgemäßem Zustand.
Verwenden Sie keine aggressiven Reinigungsmittel und ungeeignete Geräte, wie Hochdruckreiniger.
Beachten Sie, dass Kondensate aggressive und gesundheitsschädigende Bestandteile enthalten können. Deshalb sollte ein
Hautkontakt vermieden werden.
Kondensat ist ein entsorgungspflichtiger Abfall, welcher in geeigneten Behältern aufgefangen, entsorgt oder aufbereitet wer-
den muss.

16 BEKOMAT 12, 12 CO, 12 CO PN63

 Installation

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping compressed air or
through bursting plant components or plant components which are not secured.

Measures:
• Do not exceed the maximum operating pressure (see type plate)!
• Only carry out service measures when the system is pressureless.
• Use pressure-resistant installation material only.
• The feed pipe must be tubed firmly. Discharge pipe: short, fixed pressure hose onto pressure-resistant pipe.
• Make sure that persons or objects cannot be hit by condensate or escaping compressed air.

Caution!
Malfunctions in the application!
Through incorrect installation and insufficient maintenance, the BEKOMAT can malfunction. Condensate
which is not discharged can lead to damage to plants and in manufacturing processes.

Measures:
• Fail-safe condensate discharge directly optimises the compressed-air quality.
• To prevent damage and failures, it is imperative
• To comply with the provisions regarding proper use and with the operating parameters of the BEKOMAT in connection
with the case of application (see chapter "Proper use").
• To strictly adhere to the installation and operating advice in these instructions.
• To maintain and check the BEKOMAT at regular intervals in accordance with the advice in these operating instructions.

Note:

It is imperative to observe all hazard statements and warnings listed here.

Please also observe all regulations and notes regarding the industrial safety and fire prevention at the respective place of
installation.
As a matter of principle, only use suitable and appropriate tools and materials in a proper condition.
Do not use aggressive cleaners and improper devices such as high-pressure cleaners.
Please note that condensates may contain aggressive or harmful components. Therefore, skin contact should be avoided.
Condensate is subject to mandatory waste disposal and must be collected in suitable
containers, and disposed of or processed properly.

BEKOMAT 12, 12 CO, 12 CO PN63 17

 Installation

Danger !
Air comprimé !
Tout contact avec de l'air comprimé s'échappant rapidement ou de façon brutale ou tout contact avec des
parties de l'installation présentant un risque d'éclatement peut causer de graves blessures ou entraîner la mort.

Mesures préventives :
• Ne pas dépasser la pression de service maximale (voir plaque signalétique).
• Dépressuriser le purgeur avant toute intervention d'entretien ou de maintenance.
• N'utiliser que du matériel d'installation résistant à la pression.
• La conduite d'amenée doit toujours être réalisée en tuyauterie rigide et fixe. Conduite d'évacuation : flexible de faible
longueur, fixé et relié à une tuyauterie, tous deux résistant à la pression.
• Veillez à ce qu'aucune personne ni objet ne risque d'être touché par le condensat ou l'air comprimé qui s'échappe.

Prudence !
Dysfonctionnements au niveau de l'utilisation !
En cas d'installation incorrecte et de maintenance insuffisante, des dysfonctionnements peuvent apparaître
au niveau du BEKOMAT.
Tout condensat non évacué risque d'endommager les installations et de porter atteinte aux processus de
fabrication.

Mesures préventives :
• Le bon fonctionnement de la purge des condensats permet une optimisation directe de la qualité de l'air comprimé.
• Pour éviter tout endommagement et tout arrêt de production, il est impératif de respecter les consignes suivantes :
• Respecter scrupuleusement les instructions pour une utilisation conforme à l’usage prévu et les paramètres de fonc-
tionnement du BEKOMAT dans le contexte de son utilisation (consulter à cet effet le chapitre „Utilisation conforme à
l’usage prévu“).
• Respecter scrupuleusement toutes les instructions d'installation et d'utilisation communiquées dans cette notice.
• Respecter scrupuleusement la périodicité de maintenance et de contrôle du BEKOMAT selon les indications de ce
manuel d'utilisation.

Remarque :

Respectez impérativement toutes les informations relatives à un danger ou à un avertissement.

Respectez également toutes les prescriptions et consignes de sécurité relatives à la protection des travailleurs et à la protec-
tion incendie en vigueur au lieu d'installation en question.
Utilisez toujours l'outillage et le matériel appropriés et en bon état.
N'utilisez aucun produit de nettoyage agressif, ni d'appareils inadaptés, par exemple les nettoyeurs haute pression.
Notez bien que les condensats peuvent contenir des composants agressifs et néfastes pour la santé. C'est pourquoi, il est
recommandé d'éviter tout contact avec la peau.
Les condensats sont soumis à la réglementation sur les déchets. Ils doivent être collectés dans des récipients appropriés,
éliminés ou recyclés.

18 BEKOMAT 12, 12 CO, 12 CO PN63

 Installatie

Gevaar!
Perslucht!
Contact met perslucht die snel of abrupt ontsnapt of wegspringende en/of niet beveiligde delen van de ins-
tallatie leveren gevaar op met zwaar letsel of dood tot gevolg.

Maatregelen:
• Overschrijd de maximale bedrijfsdruk niet (zie instructieplaat).
• Verricht onderhoudswerkzaamheden uitsluitend in drukloze toestand.
• Gebruik uitsluitend drukbestendig installatiemateriaal.
• Verbind de toevoerleiding vast met het buizensysteem. Afvoerleiding: bevestig een korte hogedrukslang aan de drukbesten-
dige buis.
• Voorkom dat personen of voorwerpen geraakt kunnen komen door condensaat of ontsnappende perslucht.

Let op!
Storingen tijdens het gebruik!
Er kunnen storingen aan de BEKOMAT ontstaan als gevolg van een foutieve installatie en gebrekkig onder-
houd.
Niet afgevoerd condensaat kan schade veroorzaken aan installaties en in productieprocessen.

Maatregelen:
• Een veilig functionerende condensaatafvoer optimaliseert direct de persluchtkwaliteit.
• Neem het volgende absoluut in acht om schade en uitval te voorkomen:
• Correct opvolgen van de instructies voor doelmatig gebruik en van de bedrijfsparameters van de BEKOMAT afhankelijk
van de gebruikssituatie (zie hiervoor hoofdstuk "Doelmatig gebruik")
• Correct opvolgen van de installatie- en bedrijfsinstructies in deze handleiding
• Regelmatig onderhoud en controle van de BEKOMAT volgens de instructies in deze gebruiksaanwijzing

Opmerking:

Neem alle opgesomde gevaar- en waarschuwingsinstructies absoluut in acht.

Neem ook alle voorschriften en instructies in acht in verband met de arbeidsomstandigheden en brandveiligheid op de respec-
tievelijke installatieplek.
Gebruik in principe alleen maar geschikt en passend gereedschap en materiaal dat in goede staat is.
Gebruik geen aggressieve reinigingsmiddelen en ongeschikte apparaten zoals hogedrukreinigers.
Let op! Condensaat kan agressieve bestanddelen bevatten die schadelijk kunnen zijn voor de gezondheid. Daarom moet
contact met de huid worden vermeden.
Condensaat is afval dat verwijderd moet worden en in geschikte containers moet worden opgevangen, verwijderd of behan-
deld.

BEKOMAT 12, 12 CO, 12 CO PN63 19

 Installation • Installation
deutsch
Installation • Installatie

1. Zulaufrohr und Fitting mind. ½"

(Innendurchmesser > 13 mm)!
2. Keine Filter im Zulauf!
3. Gefälle im Zulauf >1% !
4. Nur Kugelventile verwenden!
5. Druck: mind. 0,8 bzw. 1,2 bar! (Druck
auf Typenschild ablesen)
6. Kurzer Druckschlauch!
7. Pro Meter Steigung in der Ablauf-
leitung, erhöht sich der erforder-
liche Mindestdruck um 0,1 bar!
Ablaufleitung max. 5 m steigend!
8. Sammelleitung mind. ½" mit 1% Ge-
fälle verlegen!
9. Bei Zulaufproblemen Entlüftungslei-
tung installieren.

falsch • wrong richtig • correct

incorrect • onjuist correct • juist

Beachte:
Druckdifferenzen!
Jede Kondensatanfallstelle muss separat
entwässert werden!

Beachte:
Entlüftung!
Bei nicht ausreichendem Gefälle im
Zulauf oder anderen Zulaufproblemen
muss eine Luftausgleichsleitung verlegt
werden!

Beachte:
Prallfläche!
Soll aus der Leitung direkt entwässert
werden, ist eine Umlenkung des Luft-
stromes sinnvoll!

20 BEKOMAT 12, 12 CO, 12 CO PN63

 english français nederlands

1. Feed pipe and fitting at least ½"! 1. Tube d'amenée, au moins ½" ! 1. Toevoerleiding en fittingen minstens
(Inner diameter > 13 mm) (Diamètre intérieur > 13 mm) ½"! (Doorlaat diameter < 13 mm)
2. No filters in feed line 2. Pas de filtre sur l'amenée ! 2. Geen filter in toevoerleiding monteren!
3. Slope in feed line > 1%! 3. Pente de l'amenée >1% ! 3. Toevoerleiding met verval monteren
4. Only use ball valves! 4. Utiliser uniquement des vannes à >1%!
5. Pressure: min. 0.8 bar or 1.2 bar! boisseau sphérique ! 4. Alleen kogelafsluiters gebruiken!
(check type plate for correct pres- 5. Pression : minimum 0,8 ou 1,2 bar! 5. Druk: minimaal 0,8 resp. 1,2 bar!
sure) (relever la pression sur la plaque) (Druk is vermeld op typeplaatje)
6. Short pressure hose! 6. Flexible pression de faible longeur! 6. Korte hogedrukslang!
7. For each metre of rising slope in the 7. Pour chaque mètre de pente montante 7. Per meter stijging in de afvoerleiding
outlet line, the required minimum pres- sur la conduite d'évacuation, il faut aug- wordt de noodzakelijke minimumdruk
sure will increase by 0.1 bar. menter la pression minimale requise verhoogd met 0,1 bar!
The rise of the outlet line must not de 0,1 bar ! Evacuation: longueur max. Afvoerleiding max. 5 m omhoog-
exceed 5 metres! de la partie montante : 5 m ! voeren!
8. Collecting line min. ½‘’ with 1% slope 8. Conduite collectrice : 8. Verzamelleiding minimaal ½" met
9. In the case of inflow problems, install au minimum ½" avec 1% de pente! minimaal 1% verval aanleggen!
venting line. 9. La conduite d'écoulement doit être 9. By problemen met aanvoer drukver-
raccordée par un col de cygne sur la eftening installeren.
conduite collectrice

Note: Important : Belangrijk:

Pressure differences! différences de pression ! Let op drukverschillen!
Each condensate source must be drained Chaque point de soutirage de condensat Ieder afvoerpunt apart draineren.
separately! doit être purgé individuellement pour éviter Het drukverschil tussen de afvoerpunten
le by-pass. Une purge continue ne serait zorgt in de kondensaatafvoerleiding voor
plus possible dans ces conditions ! een by-pass stroming.

Note: Important : Belangrijk:

Venting! équilibrage d'air ! Ontluchten!
If the feed line cannot be laid with sufficient Si la pente de l'amenée n'est pas suffi- Indien de toevoerleiding niet op afschot
slopeor if there are other inflow problems, sante, il faut poser une conduite d'équi- is gemonteerd of andere aanvoerproble-
it will be necessary to install a venting line! librage d'air ! men, moet voor de toevoer een aparte
ontluchtingsleiding worden geïnstalleerd.

Note: Important : Belangrijk:

Deflector area! chicane ! Diepste punt!
If drainage is to take place directly from a Si la purge doit s'effectuer directement sur Bij directe drainage in het leiding-systeem
line, it is advisable to arrange the piping la tuyauterie, il faut prévoir une chicane moet de BEKOMAT altijd op het diepste
so that the air flow is diverted. pour que le condensat ne soit pas entrainé punt geïnstalleerd worden. Wij adviseren
par le débit d'air comprimé ! hiervoor een broekstuk te gebruiken.

BEKOMAT 12, 12 CO, 12 CO PN63 21

 Installation • Installation
deutsch
Installation • Installatie

falsch • wrong richtig • correct

incorrect • onjuist correct • juist

Beachte:
kontinuierliches Gefälle!
Wird ein Druckschlauch als Zulauf ver-
wendet, Wassersack vermeiden!

Beachte:
kontinuierliches Gefälle!
Auch bei Verrohrung der Zulaufleitung,
Wassersack vermeiden.

22 BEKOMAT 12, 12 CO, 12 CO PN63

 EN - english

Instructions for installation and operation

Condensate drain
BEKOMAT® 32U (BM32U)
01-1611
Dear customer,
®
Thank you for deciding in favour of the BEKOMAT 32U condensate drain. Please read the installation and
®
operating instructions carefully before mounting and starting up the BEKOMAT 32U , and follow our direc-
®
tions. Perfect functioning of the BEKOMAT 32U , and thus reliable condensate discharge, can only be
guaranteed when the provisions and notes stipulated here are strictly adhered to.

2 BEKOMAT® 32U
1 Pictograms and symbols ........................................................................................................................4
2 Safety instructions ..................................................................................................................................4
3 Proper use..............................................................................................................................................5
4 Exclusion from the scope of application.................................................................................................6
5 Technical data ........................................................................................................................................7
6 Electrical data.........................................................................................................................................8
7 Dimension drawing.................................................................................................................................9
8 Climate zones and performance data ..................................................................................................10
9 Function................................................................................................................................................11
10 Installation ............................................................................................................................................15
11 Electrical installation.............................................................................................................................18
12 Control and maintenance .....................................................................................................................21
13 Troubleshooting and fault elimination ..................................................................................................24
14 Elements and components...................................................................................................................25
15 Recommended spare parts..................................................................................................................26
16 Accessories ..........................................................................................................................................26
17 Declaration of conformity .....................................................................................................................28

BEKOMAT® 32U 3
Pictograms and symbols
Pos : 1 /Beko Tec hnisc he Dokumentati on/Ü bersc hriften/1/Pi ktogramme und Symbol e @ 1\mod_1290773595840_2901.doc x @ 20524 @ 1 @ 1

1 Pictograms and symbols

Pos : 2 /Beko Tec hnisc he Dokumentati on/Pi ktogramme/Anl eitung beac hten blau @ 0\mod_1213268300255_2901.doc x @ 8336 @ @ 1

Observe the installation and operating instructions

Pos : 3 /Beko Tec hnisc he Dokumentati on/Pi ktogramme/Anl eitung beac hten s/w T ypensc hild @ 1\mod_1290772180142_2901.doc x @ 20491 @ @ 1

Observe the installation and operating instructions

(on the type plate)

Pos : 4 /Beko Tec hnisc he Dokumentati on/Pi ktogramme/Gefahr Warnung Vorsic ht s/w @ 0\mod_1213265685174_2901.doc x @ 8260 @ @ 1

General danger symbol (danger, warning, caution)

Pos : 5 /Beko Tec hnisc he Dokumentati on/Pi ktogramme/G+W+ V N etz spannung s /w @ 0\mod_1213266193701_2901.doc x @ 8298 @ @ 1

General danger symbol (danger, warning, caution) for supply voltage and supply voltage-
carrying plant components

Pos : 6 /Beko Tec hnisc he Dokumentati on/Ü bersc hriften/1/Sic herheits hinweise @ 0\mod_1183637609261_2901.doc x @ 5367 @ 1 @ 1

2 Safety instructions
Pos : 7 /Beko Tec hnisc he Dokumentati on/Gl obal e T exte/Allgemei ner Hi nweis BM @ 0\mod_1183615737313_2901.doc x @ 4006 @ @ 1
Pos : 8 /Beko Tec hnisc he Dokumentati on/Sic herheit/Hi nweis Anlei tung BEKO ( männl. N ame) @ 0\mod_1184147787557_2901.doc x @ 5760 @ @ 1

Please check whether or not these instructions correspond to the device type.
Adhere to all advice given in these operating instructions. They include essential information
which must be observed during the installation, operation and maintenance. Therefore it is
imperative for the service technician and the responsible operator / technical staff to read these
operating instructions prior to installation, start-up and maintenance.
The operating instructions must be accessible at any time at the place of application of the
®
BEKOMAT 32U .
In addition to these operating instructions, local or national regulations must be complied with,
if necessary.
®
Make sure that the BEKOMAT 32U is operated only within the permissible limit values indicat-
ed on the type plate. Any deviation involves a risk for persons and materials, and may result in
malfunction and service failures.
If you have any queries regarding these installation- and operating instructions, please contact
BEKO TECHNOLOGIES GMBH.

Pos : 9 /Beko Tec hnisc he Dokumentati on/Sic herheit/Gefahr Druc kluft @ 0\mod_1184148143854_2901.doc x @ 5778 @ @ 1

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping com-
pressed air or through bursting plant components or plant components which are not
secured.
Pos : 10 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen Druc kluft BM @ 0\mod_1184148284291_2901.doc x @ 5814 @ @ 1

Measures:
• Do not exceed the maximum operating pressure (see type plate).
• Only carry out service measures when the system is pressureless.
• Use pressure-resistant installation material only.
• The feed pipe must be tubed firmly. Discharge pipe: short, fixed pressure hose onto pressure-resistant
pipe.
• Make sure that persons or objects cannot be hit by condensate or escaping compressed air.

Pos : 11 /Beko T ec hnis che D okumentati on/Sic her hei t/Gefahr Netzs pannung 1 s/w @ 0\mod_1184148186948_2901.doc x @ 5796 @ @ 1

4 BEKOMAT® 32U
 Proper use

Danger!
Supply voltage!
There is the risk of an electric shock involving injury or death when coming into contact
with non-insulated components carrying supply voltage.
Pos : 12 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen N etzs pannung BM 31/32/33/31U/32U/33U @ 0\mod_1216898430699_2901.doc x @ 11320 @ @ 1

Measures:
• During electric installations, all regulations in force need to be adhered to (e.g. VDE 0100 / IEC 60364).
• Service measures must only be undertaken when the system is deactivated.
• The removed control unit has no IP degree of protection.
• All types of electrical works must be carried out by authorised and qualified personnel only.

Pos : 13 /Beko T ec hnis che D okumentati on/Sic her hei t/Sic herheits hinweis e, weitere BM ( nicht Ex, nic ht IF) @ 0\mod_1183616103770_2901.doc x @ 4011 @ @ 1

Further safety instructions:

• For installation and operation, the national regulations and safety codes in force must also be adhered
to.
®
• Do not use the BEKOMAT 32U in hazardous areas.
• Regarding the inlet screw joints, excessive tightening forces must be avoided. This applies in particular
to conical screw joints.
®
• The BEKOMAT 32U will only function when voltage is applied.
• Do not use the test button for permanent drainage.
• Use genuine spare parts only. This is imperative to ensure perfect functioning.
Pos : 14 /Beko T ec hnis che D okumentati on/Sic her hei t/Z usatz Sicherheits hi nweis e BM31/32 SA + 31U /32U SA @ 0\mod_1185351496993_2901.doc x @ 6480 @ @ 1

Additional advice:
• The removed control unit has no IP degree of protection.
• During installation, use spanner flat at the feed pipe (wrenchsize SW27) as a back rest.
• The service unit must not be dismantled.
Pos : 15 /Beko T ec hnis che D okumentati on/Sic her hei t/Vorsic ht F ehlfunktion @ 0\mod_1214378096290_2901.doc x @ 9360 @ @ 1

Caution!
Malfunction during operation!
Through incorrect installation and poor maintenance, malfunction may occur at the
BEKOMAT .
Condensate which is not discharged may cause damage to plants and in production
processes.
Pos : 16 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen F ehl funkti onen BM @ 0\mod_1214378434025_2901.doc x @ 9379 @ @ 1
r

Measures:
• Condensate drainage which is reliable in performance directly optimises the compressed-air quality.
• To prevent damage and breakdowns, it is imperative to observe the following:
• Exact compliance with the specifications of use and with the performance parameters of the
BEKOMAT, in connection with the case of application (see "Proper use" section)
• Exact compliance with the installation- and operation instructions in this manual
• Regular maintenance and control of the BEKOMAT in accordance with the instructions in this op-
erating manual

Pos : 17 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Besti mmungsgemäße Ver wendung @ 0\mod_1183637706293_2901.doc x @ 5385 @ 1 @ 1

3 Proper use
Pos : 18 /Beko T ec hnis che D okumentati on/Besti mmungsgemäß e Ver wendung/BEKOM AT/Bes ti mmung. Ver wend. BM 31/32/33 @ 0\mod_1213345398718_2901.doc x @ 8818 @ @ 1

®
• The BEKOMAT 32U is an electronically level-controlled condensate drain for compressed-air plants.
• The device is employed within the permissible performance parameters (see "Technical data").
®
• The BEKOMAT 32U is able to drain condensate under operating pressure from the plant components
virtually without compressed-air loss.
®
• For its function, the BEKOMAT 32U requires an supply voltage and an operating pressure (see "Tech-
nical data").
• As far as the employment in plants with increased demands on compressed air is concerned (food in-
dustry, medical technology, laboratory equipment, special processes etc.), the operator must decide on
measures for the monitoring of the compressed-air quality. These have an effect on the safety of the
subsequent processes and may prevent damage to persons and plants.

BEKOMAT® 32U 5
Exclusion from the scope of application

• It is the task of the operator to ensure that the indicated conditions are met during the entire operating
time.

Pos : 19 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Aussc hluss vom Anwendungs ber eich @ 0\mod_1236003439359_2901.doc x @ 13710 @ 1 @ 1

4 Exclusion from the scope of application

Pos : 20 /Beko T ec hnis che D okumentati on/Besti mmungsgemäß e Ver wendung/BEKOM AT/Aus schl uß Anwendung BM 31/32/33 @ 0\mod_1236003837511_2901.doc x @ 13737 @ @ 1

®
• The BEKOMAT 32U as a condensate drain alone cannot guarantee a defined compressed-air quality,
for this purpose, other additional technical devices are required.
®
• BEKOMAT 32U is not suitable for use in plants carrying vacuum or atmospheric ambient pressure or
in ex-areas.
®
• The BEKOMAT 32U must not be exposed to permanent direct solar or thermal radiation.
®
• The BEKOMAT 32U must not be installed and operated in areas with an aggressive atmosphere.
Pos : 21 /Beko T ec hnis che D okumentati on/Besti mmungsgemäß e Ver wendung/BEKOM AT/Aus schl uß Anwendung BM nic ht für fros tgefähr dete Bereic he (Zusatz) @ 0\mod_1216106439206_2901.doc x @ 11234 @ @ 1

®
• The BEKOMAT 32U is not heatable and, therefore, not suitable for the use in areas where frost is likely
to occur.
Pos : 22 /Beko T ec hnis che D okumentati on/Besti mmungsgemäß e Ver wendung/BEKOM AT/Aus schl uß Anwendung BM 31/32 nic ht fürC O2- Anwendg. @ 0\mod_1242828696240_2901.doc x @ 14880 @ @ 1

®
• The BEKOMAT 32U is not suitable for CO2 plants.
Pos : 23 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ @ 1

6 BEKOMAT® 32U
 Technical data
Pos : 24 /Beko T ec hnis che D okumentati on/Übersc hriften/1/T ec hni sche D aten @ 0\mod_1184329570967_2901.doc x @ 6058 @ 1 @ 1

5 Technical data
Pos : 25 /Beko T ec hnis che D okumentati on/Tec hnische D aten/BEKOM AT/T ec hn. D aten BM 3xU + UC + GOST (o.Leistg.) @ 5\mod_1358843578945_2901.doc x @ 30450 @ @ 1

0,8...16 bar (12...230 psi)

min./max. operating pressure
or
(see type plate)
1,2...16 bar (17...230 psi)
+1...+60 °C (+34...+140 °F)
min./max. temperature
or
(see type plate)
+1...+70 °C (+34...+158 °F)
G ½ (½") internal
Condensate inflow
max. screw-in depth 13,5 mm (½")
Condensate outflow G ¼ (¼") Ø 8 ... 10 mm hose connector
Condensate oil-contaminated + oil-free
Housing aluminium + plastic, glass fibre-reinforced
Weight (empty) 1,0 kg (2.2 lbs)
This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1-12, third edition, includ-
ing a later version of the same standard incorporation the same level of testing requirements.

Pos : 26 /Beko T ec hnis che D okumentati on/Tec hnische D aten/BEKOM AT/Leis tung BM Standar d @ 0\mod_1184050678383_2901.doc x @ 5720 @ @ 1

Max. performance for the "blue" climate zone – see also Chapter "Climate zones and performance data"
max. compressor performance 5 m³/min (175 scfm)
max. refrig.-dryer performance 10 m³/min (350 scfm)
max. filter performance 50 m³/min (1750 scfm)

Pos : 27 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

BEKOMAT® 32U 7
Electrical data
Pos : 28 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Elektrische D aten @ 0\mod_1183638451371_2901.doc x @ 5601 @ 1 @ 1

6 Electrical data
Pos : 29 /Beko T ec hnis che D okumentati on/El ektrisc he Daten/BEKOM AT/Elektrische D aten BM 32U/33U @ 4\mod_1357737405732_2901.doc x @ 29582 @ 1 @ 1

95…240 VAC ±10% (50…60 Hz) /100…125 VDC ±10%

Supply voltage
or
(see type plate)
24…48 VAC ±10% (50…60 Hz) / 18…72 VDC ±10%
Power consumption P = 0,6 ... 3 VA (W)
Recommended cable-jacket di-
Ø 5,0…10 mm (0,20“…0,39“)
ameter
Recommended
wire cross-section
0,75...1,5 mm² (AWG 16...20)
Spring-loaded terminal
(voltage supply/relay)
Recommended
wire cross-section
0,75...2,5 mm² (AWG 14...20)
Screw terminal
(voltage supply)
Recommended
wire cross-section
0,75...1,0 mm² (AWG 18...20)
Spring-loaded terminal
(external test)
Recommended
wire cross-section
0,75...1,5 mm² (AWG 16...20)
Screw terminal
(relay/external test)
Recommended stripping of cable
jacket ~ 30 mm (~ 1.18")
(voltage supply/relay)
Recommended stripping of cable
jacket ~ 90 mm (~ 3.54")
(external test)
Recommended length of the wire
end tube ~ 8 mm (~ 0.31 inch)
Spring-loaded terminal
Recommended length of the wire
end tube ~ 6 mm (~ 0.24 inch)
Screw terminal
Connection data of the potential-
AC: max. 250V / 1A
free contact
DC: max. 30V / 1A
Switch to load *)
Connection data of the potential-
free contact min. 5 VDC / 10 mA
Switch to low signal *)
Connection data of the external
on the unit side 5 VDC; switching current ≥ 0,5 mA
test contact
Protection class IP 67
Overvoltage category
II
(IEC 61010-1)
VAC = V alternating current
VDC = V direct current
*) The switching of loads means that the properties of the contact are no longer suitable
for the switching of low signals.
Pos : 30 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

8 BEKOMAT® 32U
 Dimension drawing
Pos : 31 /Beko T ec hnis che D okumentati on/Übersc hriften/1/M aßz eichnung @ 0\mod_1183638072605_2901.doc x @ 5493 @ 1 @ 1

7 Dimension drawing
Pos : 32 /Beko T ec hnis che D okumentati on/Tec hnische D aten/M assz eichnung @ 0\mod_1184569815280_2901.doc x @ 6140 @ 1 @ 1

Pos : 33 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

BEKOMAT® 32U 9
Climate zones and performance data
Pos : 34 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Kli maz onen und Leistungs daten @ 0\mod_1183638385480_2901.doc x @ 5583 @ 1 @ 1

8 Climate zones and performance data

Pos : 35 /Beko T ec hnis che D okumentati on/Kli mazonen/Kli maz onen BM @ 0\mod_1184573462796_2901.doc x @ 6180 @ 1 @ 1

Max. Max. Max. filter performance

compressor perfor- dryer performance
Climate zone mance m³/min. m³/min.
m³/min.
green 6,0 12,0 60,0
blue 5,0 10,0 50,0
red 3,5 7,0 35,0
The indicated performance data are based on a moderate climate and apply to Europe, large parts of South-
east Asia, North and South Africa, parts of North and South America (climate zone: blue).
For dry and / or cool climate (climate zone: green) , the following factor applies: performance in the "blue"
climate zone approx. x 1.2
For warm and / or humid climate (tropics; climate zone: red), the following factor applies: performance in the
"blue" climate zone approx. x 0.7
Pos : 36 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

10 BEKOMAT® 32U
 Function
Pos : 37 /Beko T ec hnis che D okumentati on/Übersc hriften/1/F unkti on @ 0\mod_1183637775808_2901.doc x @ 5403 @ 1 @ 1

9 Function
Pos : 38 /Beko T ec hnis che D okumentati on/Funkti on/BEKOMAT/BM Ablei tfunktion @ 0\mod_1183618031702_2901.doc x @ 4032 @ @ 1

Via the inlet line (1) the condensate flows into the
®
BEKOMAT 32U and accumulates in the housing (2).
A capacitively functioning sensor (3) continuously
registers the filling level and relays a signal to the
electronic control as soon as the container is filled.

The pilot valve (4) is activated and the membrane (5)

opens the outlet line to discharge the condensate (6).
When the BEKOMAT BEKOMATis empty, the outlet
line is reclosed tightly in time before unnecessary
compressed-air losses occur.

Pos : 39 /Beko T ec hnis che D okumentati on/Funkti on/BEKOMAT/BM 32U/33U LED-T aster-Funkti on @ 4\mod_1354691493582_2901.doc x @ 29040 @ @ 1

BEKOMAT® 32U 11
Function

At the BEKOMAT 32U, two LEDs indicate the individ-

ual operating states.

When applying supply voltage, the BEKOMAT 32U

carries out a self-test.
Both LEDs are lit for approximately 1 second, subse-
quently, the device changes over to the "ready-to-
operate" state.

Ready to operate, voltage is applied.

In the event that the condensate discharge is dis-

turbed, an alarm mode will start which is indicated by
the flashing of the red alarm LED.
Malfunction/alarm

Test of the valve function (manual drainage): press

and hold the button for approximately 2 s.
Test of the alarm function (see below): press and hold
the button for at least 1 min.
Do not use for permanent drainage.

Pos : 40 /Beko T ec hnis che D okumentati on/Funkti on/BEKOMAT/BM- Alar mmodus ( nicht Vario) @ 0\mod_1185868789656_2901.doc x @ 6850 @ 1 @ 1
.

12 BEKOMAT® 32U
 Function

Switching sequence of the valve in the alarm Alarm mode:

mode In the event that the condensate discharge is dis-
turbed, the valve opens after a time cycle (approx.
every three seconds) to eliminate the malfunction
automatically. If the malfunction is not eliminated after
one minute, a trouble indication is released:
• The alarm LED flashes
• The alarm relay switches over (the signal can be
picked off potential-freely).
• The valve opens every four minutes for 7.5 sec-
onds.
• When the malfunction has been eliminated, the
BEKOMAT will switch back automatically into the
normal mode.
Possible trouble sources include:
Trouble indication via a potential-free contact • Mistakes during installation
• Dropping below the minimum pressure
• Excessive accumulation of condensate (excess
load)
• Blocked / obstructed outlet line
• Extreme amount of dirt particles
• Frozen pipework

Pos : 41 /Beko T ec hnis che D okumentati on/Funkti on/BEKOMAT/BM 31U/32U/33U ( nic ht 32U FMK) Wartungs meldung @ 5\mod_1371731964818_2901.doc x @ 31020 @ 1 @ 1

®
The BEKOMAT 32U releases a maintenance mes-
sage for a service that is to be carried out.

Depending on the operating mode, a visual mainte-

nance message (service) is activated which signalises
the replacement of the service unit.

The maintenance message is indicated by the flashing

supply voltage-LED "Power".

The maintenance message is released after 2 x 8,760

h or one million switching cycles.
The maintenance signal is released when one of
these two values is reached.

In the event of a power outage or when the energy

supply is deactivated, the status of the timer will be
maintained.

The activities to be carried out regarding maintenance

are described in the chapter entitled "Check and
maintenance".

BEKOMAT® 32U 13
Function

Prior to the replacement of the service unit, a reset

needs to be carried out. The control unit is released by
actuating the arresting hook. When removed, the
TEST button must be pressed and held for at least
five seconds.

Pos : 42 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

14 BEKOMAT® 32U
 Installation
Pos : 43 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Ins tall ati on @ 0\mod_1183637835418_2901.doc x @ 5421 @ 1 @ 1

10 Installation
Pos : 44 /Beko T ec hnis che D okumentati on/Sic her hei t/Gefahr Druc kl uft @ 0\mod_1184148143854_2901.doc x @ 5778 @ @ 1

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping com-
pressed air or through bursting plant components or plant components which are not
secured.
Pos : 45 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen Druc kluft BM @ 0\mod_1184148284291_2901.doc x @ 5814 @ @ 1

Measures:
• Do not exceed the maximum operating pressure (see type plate).
• Only carry out service measures when the system is pressureless.
• Use pressure-resistant installation material only.
• The feed pipe must be tubed firmly. Discharge pipe: short, fixed pressure hose onto pressure-resistant
pipe.
• Make sure that persons or objects cannot be hit by condensate or escaping compressed air.

Pos : 46 /Beko T ec hnis che D okumentati on/Sic her hei t/Vorsic ht F ehlfunktion @ 0\mod_1214378096290_2901.doc x @ 9360 @ @ 1

Caution!
Malfunction during operation!
Through incorrect installation and poor maintenance, malfunction may occur at the
BEKOMAT .
Condensate which is not discharged may cause damage to plants and in production
processes.
Pos : 47 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen F ehl funkti onen BM @ 0\mod_1214378434025_2901.doc x @ 9379 @ @ 1
r

Measures:
• Condensate drainage which is reliable in performance directly optimises the compressed-air quality.
• To prevent damage and breakdowns, it is imperative to observe the following:
• Exact compliance with the specifications of use and with the performance parameters of the
BEKOMAT, in connection with the case of application (see "Proper use" section)
• Exact compliance with the installation- and operation instructions in this manual
• Regular maintenance and control of the BEKOMAT in accordance with the instructions in this op-
erating manual

Pos : 48 /Beko T ec hnis che D okumentati on/Sic her hei t/Hinweis Ins tall ati on und Wartung @ 0\mod_1233239666823_2901.doc x @ 13340 @ 1 @ 1

Note:

It is imperative to observe all hazard statements and warnings listed here.

Please also observe all regulations and notes regarding industrial safety and fire prevention at the place of
installation.
As a matter of principle, only use suitable and appropriate tools and materials in a proper condition.
Do not use aggressive cleaners and improper devices such as high-pressure cleaners.
Please note that condensates may contain aggressive or harmful components. Therefore, skin contact
should be avoided.
Condensate is subject to mandatory waste disposal. As such, it must be collected in suitable containers, and
disposed of or processed properly.

Pos : 49 /Beko T ec hnis che D okumentati on/Installati on/BEKOMAT /BM 31/32/33+U+AU (nic ht Vario) Installations hinweise @ 0\mod_1184161640511_2901.doc x @ 5876 @ 1 @ 1

BEKOMAT® 32U 15
Installation

Installation instructions:

• Only the displayed installation position of the

BEKOMAT (3) is permissible. Never install in a hor-
izontal or any other tilted position.
• Feed pipe (1) and ball valve (2) at least G½.
• No filter or screen in the inlet line.
• Slope in the inlet line >1%.
• Use ball valves (2) only.
• Operating pressure: min. 0,8/1,2 bar (12/17 psig),
max. 16 bar (230 psig). See type plate.
• Short pressure hose (4) fixed on a pressure-
resistant pipe.
• The required minimum pressure increases by
0,1 bar (1,4 psi) per metre gradient in the dis-
charge pipe (5).
• Discharge pipe (5) rising by max. 5 m (16,4ft).
• Install manifold (6) ½" with a slope of 1%.
• Introduce the discharge pipe (5) from the top into
the manifold (6).
• Prior to the start-up, always carry out a leak test
and verify the correct engagement of the control
unit.

16 BEKOMAT® 32U
 Installation

wrong correct

Pressure differences!

Each condensate accumulation point must be drained

separately.

Continuous slope!

Avoid a water pocket when installing the feed pipe

Deflector area!

If drainage is to be carried out directly from the pipe,

deflection of the air flow will be useful.

Ventilation!

If the slope in the inlet line is not sufficient or if any

other inflow problems occur, a venting line needs to be
installed.

Pos : 50 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

BEKOMAT® 32U 17
Electrical installation
Pos : 51 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Elektrische Install ati on @ 0\mod_1183638507355_2901.doc x @ 5619 @ 1 @ 1

11 Electrical installation
Pos : 52 /Beko T ec hnis che D okumentati on/Sic her hei t/Gefahr Netzs pannung 1 s/w @ 0\mod_1184148186948_2901.doc x @ 5796 @ @ 1

Danger!
Supply voltage!
There is the risk of an electric shock involving injury or death when coming into contact
with non-insulated components carrying supply voltage.
Pos : 53 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen N etzs pannung BM 31/32/33/31U/32U/33U @ 0\mod_1216898430699_2901.doc x @ 11320 @ @ 1

Measures:
• During electric installations, all regulations in force need to be adhered to (e.g. VDE 0100 / IEC 60364).
• Service measures must only be undertaken when the system is deactivated.
• The removed control unit has no IP degree of protection.
• All types of electrical works must be carried out by authorised and qualified personnel only.

Pos : 54 /Beko T ec hnis che D okumentati on/Installati on/BEKOMAT /El ektrInstallation Hi nweis e BM32U/33U allg. @ 4\mod_1357728884079_2901.doc x @ 29514 @ @ 1

Note:

Power supply connection:

1. Read the permissible supply voltage on the type
plate and make sure this voltage is observed.
2. For the supply voltage, a reliably accessible sepa-
rator must be provided close-by (e.g. power plug
or switch), which separates all current-carrying
conductors.
3. At a low-voltage supply
(< 50 VAC / < 75 VDC), only use a protective ex-
tra-low-voltage (PELV).
4. Carry out installation in accordance with
VDE 0100 / IEC 60364.
5. Observe the terminal assignment.
6. Do not install when the device is energised.
7. Unscrew the screws (1) and remove the upper
part of the cover (2).
8. Unscrew the threaded cable connection (3), re-
move the plug (if there is one), and lead the cable
(4) for the power supply through.
9. Connect the cable (4) with terminals X1 (1.1, 1.2)
(5).
10.Install the cables as shown (see also terminal
assignment in the following text).
11.Tighten the threaded cable connection (3) with a
slightly sealing effect.
12.Put on the upper part of the cover (2) and tighten
the screws (1) fingertight.

18 BEKOMAT® 32U
 Electrical installation

Connection of the potential-free contact and of

the external test:
1. Selection of the suitable cable.
2. Connection to X2 and X3, as shown in the adja-
cent illustration.
3. The installation steps are the same as for the
power supply connection.
4. If the potential-free contact carries voltage that is
dangerous in the case of contact, a corresponding
separator must also be provided, as described
above.
5. When using the potential-free contacts and the
connection external test, sufficient clearance to
the other parts of the unit, or suitable insulation in
accordance with EN 60664-1 must be ensured.
6. When using a multiwire, common line for the con-
nection of the potential-free contact and the exter-
nal test, this line must be suitable for the highest
occurring voltage and the intended temperature
range with regard to its nominal ratings.

Pos : 55 /Beko T ec hnis che D okumentati on/Installati on/BEKOMAT /Kl emmenbel egung BM 32U/33U @ 4\mod_1354692952721_2901.doc x @ 29108 @ 1 @ 1

Terminal assignment supply voltage (operating voltage)

X1 X2 X3 • X 1.1 L mains connection
1 2 1 2 3 1 2 • X 1.2 N mains connection
external test (IN1)

L = Outer conductor
normally closed

N = Neutral conductor
normally open

common
neutral
phase

GND
2.1

2.2

2.3

3.1

3.2
1.1

1.2

Terminal assignment low voltage (operating voltage)

X1 X2 X3 • X 1.1 Power supply
1 2 1 2 3 1 2 • X 1.2 Power supply
external test (IN1)
normally closed
normally open

common
power

power

GND
2.1

2.2

2.3

3.1

3.2
1.1

1.2

BEKOMAT® 32U 19
Electrical installation

Terminal assignment of the potential-free contact and of the external test

X1 X2 X3 Alarm / potential-free contact:
1 2 1 2 3 1 2 • X 2.1 n.o.
• X 2.2 com.
• X 2.3 n.c.

external test (IN1)

normally closed n.c. - com. closed in the event of malfunction or power failure
normally open

(closed current principle)

n.o. - com. closed during normal operation
common
power

power

The contacts X2.1 - 2.3 are potential-free.

GND External test / remote control:
• X 3.1 external test (IN1)
2.1

2.2

2.3

3.1

3.2
1.1

1.2

• X 3.2 GND
Contacts connected = test active = discharge
Contacts open = test inactive
The contacts X 3.1 -3.2 are not potential-free.

Note:

At a low-voltage supply
(< 50 VAC / < 75 VDC), only use a protective extra-low-voltage (PELV).
Tighten the threaded cable connection with a slightly sealing effect.

Pos : 56 /Beko T ec hnis che D okumentati on/Installati on/BEKOMAT /E- Schema @ 0\mod_1233758178163_2901.doc x @ 13497 @ 1 @ 1

Electric diagram
Pos : 57 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

20 BEKOMAT® 32U
 Control and maintenance
Pos : 58 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Kontr olle und Wartung @ 0\mod_1183637885371_2901.doc x @ 5439 @ 1 @ 1

12 Control and maintenance

Pos : 59 /Beko T ec hnis che D okumentati on/Sic her hei t/Gefahr Druc kl uft @ 0\mod_1184148143854_2901.doc x @ 5778 @ @ 1

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping com-
pressed air or through bursting plant components or plant components which are not
secured.
Pos : 60 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen Druc kluft BM @ 0\mod_1184148284291_2901.doc x @ 5814 @ @ 1

Measures:
• Do not exceed the maximum operating pressure (see type plate).
• Only carry out service measures when the system is pressureless.
• Use pressure-resistant installation material only.
• The feed pipe must be tubed firmly. Discharge pipe: short, fixed pressure hose onto pressure-resistant
pipe.
• Make sure that persons or objects cannot be hit by condensate or escaping compressed air.

Pos : 61 /Beko T ec hnis che D okumentati on/Sic her hei t/Gefahr Netzs pannung 1 s/w @ 0\mod_1184148186948_2901.doc x @ 5796 @ @ 1

Danger!
Supply voltage!
There is the risk of an electric shock involving injury or death when coming into contact
with non-insulated components carrying supply voltage.
Pos : 62 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen N etzs pannung BM 31/32/33/31U/32U/33U @ 0\mod_1216898430699_2901.doc x @ 11320 @ @ 1

Measures:
• During electric installations, all regulations in force need to be adhered to (e.g. VDE 0100 / IEC 60364).
• Service measures must only be undertaken when the system is deactivated.
• The removed control unit has no IP degree of protection.
• All types of electrical works must be carried out by authorised and qualified personnel only.

Pos : 63 /Beko T ec hnis che D okumentati on/Sic her hei t/Vorsic ht F ehlfunktion @ 0\mod_1214378096290_2901.doc x @ 9360 @ @ 1

Caution!
Malfunction during operation!
Through incorrect installation and poor maintenance, malfunction may occur at the
BEKOMAT .
Condensate which is not discharged may cause damage to plants and in production
processes.
Pos : 64 /Beko T ec hnis che D okumentati on/Sic her hei t/Maßnahmen F ehl funkti onen BM @ 0\mod_1214378434025_2901.doc x @ 9379 @ @ 1
r

Measures:
• Condensate drainage which is reliable in performance directly optimises the compressed-air quality.
• To prevent damage and breakdowns, it is imperative to observe the following:
• Exact compliance with the specifications of use and with the performance parameters of the
BEKOMAT, in connection with the case of application (see "Proper use" section)
• Exact compliance with the installation- and operation instructions in this manual
• Regular maintenance and control of the BEKOMAT in accordance with the instructions in this op-
erating manual

Pos : 65 /Beko T ec hnis che D okumentati on/Sic her hei t/Hinweis Ins tall ati on und Wartung @ 0\mod_1233239666823_2901.doc x @ 13340 @ 1 @ 1

BEKOMAT® 32U 21
Control and maintenance

Note:

It is imperative to observe all hazard statements and warnings listed here.

Please also observe all regulations and notes regarding industrial safety and fire prevention at the place of
installation.
As a matter of principle, only use suitable and appropriate tools and materials in a proper condition.
Do not use aggressive cleaners and improper devices such as high-pressure cleaners.
Please note that condensates may contain aggressive or harmful components. Therefore, skin contact
should be avoided.
Condensate is subject to mandatory waste disposal. As such, it must be collected in suitable containers, and
disposed of or processed properly.

Pos : 66 /Beko T ec hnis che D okumentati on/Wartung/BEKOM AT/Wartung BM 31U /Wartung BM 31U/32U ( nic ht IF) stand-al one 2x8760h @ 5\mod_1358509672852_2901.doc x @ 30344 @ 1 @ 1

Maintenance recommendation:
After 2 x 8,760 operating hours or one million switch-
ing cycles, a maintenance message is released.
The green power LED flashes. Afterwards, or at the
latest after two years (2 x 8,760 operating hours), the
service unit (5) needs to be replaced.

1. Prior to the replacement of the service unit, a reset

needs to be carried out. The control unit is re-
leased by actuating the arresting hook. When re-
moved, the TEST button below the LED must be
pressed and held for at least five seconds.

2. Remove the control unit (1) by pressing the arrest-

ing hook (2)
3. Unfasten the BEKOMAT 32U from the outlet (3).
4. Remove the design shell (4) (if there is one) using
a screwdriver (10).
5. Detach the service unit (5) from the tubing at the
inlet by removing the union nut.
6. or remove the screws (6) from the angle nozzle
(7).

22 BEKOMAT® 32U
 Control and maintenance

7. or remove the screws (8) at the intermediate

adapter (9) and remove the latter from the service
unit by pulling it downwards.
8. Check whether or not the new service unit (5) goes
with the control unit (1).
(model designation and colour of the arresting
hook (2)).

9. Installation of the new service unit (5) in reverse

order.

Installation of the control unit on the service unit:

1. Check whether or not the service unit (5) goes with
the control unit (1) (model designation and colour
of the arresting hook).
2. Check whether or not the sealing mat (11) and the
contact springs (13) are clean, dry, and free from
impurities.
3. Introduce the sensor (12) into the sensor tube plate
(14).
4. Hang the hook (15) of the control unit (1) in the
sensor tube plate (14).
5. Press the control unit (1) against the service unit
(5) and snap into place.

Start-up subsequent to maintenance measures:

Always carry out prior to the start-up:
• Leak test of the screwed connector
• Check of the electrical connections
• Check of the correct engagement of the control unit

Pos : 67 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

BEKOMAT® 32U 23
Troubleshooting and fault elimination
Pos : 68 /Beko T ec hnis che D okumentati on/Übersc hriften/1/F ehlers uc he und Fehl erbehebung @ 0\mod_1183637945027_2901.doc x @ 5457 @ 11 @ 1

13 Troubleshooting and fault elimination

Pos : 69 /Beko T ec hnis che D okumentati on/Fehlers uc he/BEKOMAT /Fehl ersuc he BM 32U/32UV/33U/33U V @ 4\mod_1357742330741_2901.doc x @ 29650 @ 1 @ 1

Symptoms Possible reasons Measures

Supply voltage incorrect Check voltage on the ID plate

Circuit board defective Check the connections and the supply
voltage
Check the circuit boards for possible
damage
No LED lights up

Failure during the start of the pro- Separate the device from the supply
gramme voltage and reactivate after > 5 s
Circuit board defective Check the circuit boards for possible
damage

All LEDs are continuously

on
Feed pipe and/or discharge pipe Check feed and discharge pipe
blocked or obstructed Check whether or not the valve opens
Wear and tear audibly (press the test button several
Circuit board defective times for >2 seconds)
Service unit defective Check the circuit board for possible
damage
Minimum pressure not reached
Check the operating pressure
Test button pressed, Maximum pressure exceeded
but no condensate
discharge
Feed pipe without sufficient slope Install feed pipe with a slope
Cross section not large enough Replace the service unit
Condensate accumulation too high
(surge)
Service unit extremely dirty

Condensate discharge
only when the test but-
ton is pressed
Service unit defective or dirty Replace the service unit

Device blows off con-

tinuously

Pos : 70 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

24 BEKOMAT® 32U
 Elements and components
Pos : 71 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Bauteile und Komponenten @ 0\mod_1183638014355_2901.doc x @ 5475 @ 11 @ 1

14 Elements and components

Pos : 72 /Beko T ec hnis che D okumentati on/Bauteil e und Komponenten/BEKOMAT/Bauteil e BM 32U s tand-al one @ 4\mod_1358417886920_2901.doc x @ 29966 @ 1 @ 1

1 Screw 3.5 x 10 9 Service unit

2 Upper part of the cover 10 Hose connector G¼
3 Cord packing 2 x 352 11 O-ring 20 x 2
4 Circuit board 12 Intermediate adapter
5 Sensor 13 Screw M6 x 12
6 Lower part of the cover 14 O-ring 14 x 1.78
7 Cable bushing 15 Angle adaptor G½
8 Sealing mat 16 Design shell

Pos : 73 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 11 @ 1

BEKOMAT® 32U 25
Recommended spare parts
Pos : 74 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Empfohl ene Ersatzteile @ 0\mod_1183638186183_2901.doc x @ 5529 @ 111 @ 1

15 Recommended spare parts

Pos : 75 /Beko T ec hnis che D okumentati on/Ers atzteile Zubehör/BEKOM AT/Ersatzteile BEKOMAT 32U @ 4\mod_1358418107278_2901.doc x @ 30102 @ 1 @ 1

Available sets of spare parts Contents Order number

Service unit 9, 11* 4023571
Gasket kit 3, 8, 11* 4024392
Design shell* 16* 4010167
Connection adapter* 11, 12, 13, 14, 15 4010155
* Not for BEKOMAT 32U built-in

Pos : 76 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Z ubehör @ 0\mod_1232362905455_2901.doc x @ 13030 @ 1 @ 1

16 Accessories
Pos : 77 /Beko T ec hnis che D okumentati on/Ers atzteile Zubehör/BEKOM AT/H altewinkel BM 31/32 SA @ 0\mod_1232368058757_2901.doc x @ 13057 @ 1 @ 1

Available accessory sets Contents Order number

Mounting brackets 1 Mounting bracket
for wall and base 4010105
2 Extension G ½ 20 long

Pos : 78 /Beko T ec hnis che D okumentati on/Ers atzteile Zubehör/BEKOM AT/Abl auf-Set BM 31/32 @ 0\mod_1232623241656_2901.doc x @ 13254 @ 1 @ 1

26 BEKOMAT® 32U
 Accessories

Available accessory sets Contents Order number

Outlet set Tubing piece 10x3x800
With a hose and Grommet 9-G½ Ms 2000045
installation material Hose clamp 12-22/9 A2

Pos : 79 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ 1 @ 1

BEKOMAT® 32U 27
Declaration of conformity
Pos : 80 /Beko T ec hnis che D okumentati on/Übersc hriften/1/Konfor mitäts er klär ung @ 0\mod_1210752269256_2901.doc x @ 8060 @ 1 @ 1

17 Declaration of conformity
Pos : 81 /Beko T ec hnis che D okumentati on/Zertifi kate/Er klär ung en/BEKOMAT 31U-33U-EG-Konfor mSc an @ 5\mod_1358418648413_0.doc x @ 30238 @ @ 1

Pos : 82 /---- Seitenumbr uch ---- @ 0\mod_1157028099015_0.doc x @ 2903 @ @ 1

28 BEKOMAT® 32U
 Declaration of conformity
Pos : 83 /Beko T ec hnis che D okumentati on/Zertifi kate/Er klär ung en/BEKOMAT 31U-33U-EG-Konfor mWord @ 5\mod_1358418687242_2901.doc x @ 30272 @ @ 1

BEKO TECHNOLOGIES GMBH

41468 Neuss, GERMANY
Tel: +49 2131 988-0
www.beko-technologies.com

EC Declaration of Conformity

We hereby declare that the products indicated hereafter comply with the stipulations of the relevant direc-
tives and technical standards. This declaration only refers to products in the condition in which they have
been placed into circulation. Parts which have not been installed by the manufacturer and/or modifications
which have been implemented subsequently remain unconsidered.

Product designation: Condensate drain

Types: BEKOMAT 31U, 32U, 32UV, 33U, 33UV
Voltage options: 95…240 VAC ±10% (50…60 Hz) / 100…125 VDC ±10%
or
24...48 VAC ±10% (50…60 Hz) / 18...72 VDC ±10%
Operating pressure range: 0.8…16 bar (12…230 psi)
or
1.2…16 bar (17…230psi)
Product description and function: Condensate drain for the electronically level-controlled
discharge of condensate in the compressed-air system.

Low-Voltage Directive 2006/95/EC

Harmonised standards applied: EN 61010-1:2010
Year of CE labelling: 13
The devices with a supply voltage of 24...48 VAC and 18...72 VDC do not come under the scope of the Low-
Voltage Directive.

EMC Directive 2004/108/EC

Harmonised standards applied: EN 61326-1:2006
EN 55011:2009 + A1: 2010, group 1, class B

RoHs Directive 2011/65/EU

The stipulations of the 2011/65/EU Directive on the restriction of the use of certain hazardous substances in
electrical and electronic equipment are observed.

Neuss, 21 August 2013 BEKO TECHNOLOGIES GMBH

p.p. Christian Riedel

Head of Quality Department

Pos : 84 /Beko T ec hnis che D okumentati on/Globale Texte/Hinweis Ü bers etzg. d. Orig.anl eitg. @ 1\mod_1260433478358_2901.doc x @ 17104 @ @ 1
Pos : 85 /Beko T ec hnis che D okumentati on/Globale Texte/Hinweis Original anl eitung @ 1\mod_1260433346280_2901.doc x @ 17070 @ @ 1
Pos : 86 /Beko T ec hnis che D okumentati on/Globale Texte/Vorbehalts klaus el @ 0\mod_1213704033153_2901.doc x @ 9298 @ @ 1
=== Ende der Liste für T extmar ke Inhalt ===

BEKOMAT® 32U 29
 1 2 3 4 5 6 7 8
126
113 220
A A
107 20205
on troll- und Entl uftungsschraube
Control and venting screw 101 120 165

Ln
N Ln Ln
.._....-- C) C)
B .._....-- .._....--
B
I C)
- - --+-- - ____D c--
.._....-- Ln
'-[)
N N
I
"'\~
Ln \:)
N
.._....--

[ [
1- G 112

ondensatable iter Ri fox EF 1281

150 PN 40, G 1/2, Art-Nro 0097073
M10 Werkstoff P235GH, P250GH, P265GH

-Stahl U60, DIN 1026-1, L=70

D
C)
C) Ln Werkstoff S235JRG2, EN 10025 D
.._....-- c-- angeschwe i Bt

-·--
I

Ln C) 1----------tial ter 200x60 t=6, Ha_30144

co
C)
N
0
Ln
Ln
0'
. © C)
N Werkstoff S235JRG2, EN 10025
1x angeschwe i Bt
.._....--
1x geschraubt
© 2x Schraube M10x25 -Kl. 5.6,
2x Mutter M10 Kl 0 5-2
E E
2 Schraubenlochkreis 22.5' gedreht. Entluftungsschra 18.03.2010 Scheppm.
Hal teblech ge ondert 28.04.2009 Scheppm.
0 08.04.2009 Scheppm.
Index Anderung Datum Name
Schw i mmerkondensatable iter Typ Ri fox EF 1281, PN 40, G 1/2 Datum Name W erkstoff-Daten Bez. (altl:
mit angeschwe i Btem Halter Gez. 08.04.2009 Scheppm. Nr .: Bez. (0 IN ENl: NEUENHAUSER
Abnahme: EN 10204-3.1 Gepr. 18.03.2010 Scheppm. Halbzeug Abmessung KOMPRESSORENBAU
Status Freigegeben D-49828 NEUENHAUS
TELEFON (05941) 604-0
wei tere Abnahmen z .B. EN 10204-3.2 oder "[ E" PED 97 /23/EC Schutzvermerk nach TELEFAX (05941) 604-202

werden auftragsbezogen festgelegt

DIN ISO 16016 beachtenl PC 50 e-mail NKoneuenhauser .de
F Allgemein- MaBstab Art. Nr. 1030559 F
toleranz Kondensatable iter mit Halter z. Nr. Zu_30876
ISO 2768-mk
3:10 float trap with support Index 2 Blatt -Nr .: 1 von
Rifox EF 1281, PN 40, G 112 Ersatz fur:
Ersetzt durch:
ZU_30876-0-2 2 3 4 5 6 7 8 A3
 Operating Manual

Model: 1210 / 1210-N

Model: 1281 / 1281-N
Float-Controlled Condensate Trap, PN 40
1 Safety instructions
1.1 Proper use
Any improper use, intervention in the design and deviation from the design data automatically lead to termination of the
warranty. The float-controlled condensate trap is designed for the discharge of condensate from steam, compressed air and
pressure gas systems. Any other usage is not permitted. The manufacturer is not liable for damage resulting from any other
usage. The user or operator bears the risk in this case. This also applies analogously to incorrect assembly, start-up, use and
maintenance.
1.2 Warnings and symbols
■ Personal risk due to escaping operating medium because of pressure, temperature and weight. Failure to comply with
these warnings results in the risk of accidents.
■ Follow the instructions in this operating manual.
■ The operator must ensure that this operating manual and, if necessary, other relevant documents are available on site.
■ Only trained or instructed personnel may be assigned to handling this equipment.
■ Any mode of operation that may impair safety must be avoided.
2 General description and usage
2.1 Design of the condensate trap

12 04
05
01 05
01 12
02 02 10

03
08 08
07 07

03 09 09

11 11 06
06
01 Housing cover 07 Float control assembly
02 Housing gasket 08 Supporting body assembly
03 Housing 09 Float
04 Control valve 10 Control screw
05 Housing screws 11 Gasket
06 3CREW pluG 12 'Asket

2.2 Operation limits of housing material (Design)

max. operating pressure (bar g) 40 37,1 33,3 27,6 23,8

for 1210-1281:
max. operating temperature (°C) -10/20 100 200 300 400
06/2016 -Di. Subject to modifications

max. operating pressure (bar g) 40 37 33 30

for 1210N-1281N:
max. operating temperature (°C) -60/100 200 300 400
Page 1 of 5

RIFOX - Hans Richter GmbH Spezialarmaturen Fon: +49 (0) 421 499 75 - 0 www.rifox.de [email protected]
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: +49 (0) 421 499 75 - 40 www.rifoxglobal.com [email protected]
 Operating Manual

2.3 Function limit of control unit

max. line pressure in bar g
Cross-section
Steam Compressed air
II a 30 40
III 12 16
IV 10 14
V 2,6 3
VI 21 32
VI a 29 29
VII 18 23
VIII a 4,9 6
VIII b 4 5

2.4 Discharge capacity (for hot condensate)

15000
10000
DN15-25: IIa / III / IV / V
7000
DN40/50: VI / VI a / VII / VII a / VIII b
5000

3000

2000
Discharge capacity in kg/h

1000
700
500

300
200

100
70
50
40
32

Pressure difference in psi (with reference to atmospheric pressure)

Picture 3
For the hot condensate the discharge capacity is lower because of medium temperature and density.
2.5 Function
■ Due to the gravity the condensate flows downwards to the lowest point, which is the condensate trap housing. In the
lowest position of the float the outlet cross-section is close. Rising of the liquid level lifts the float and opens the outlet.
Condensate will be discharged through the upturned immersion tube. Decreasing condensate level closes the outlet again.
2.6 Compensation line
■ In order to get proper function, the non-condensable gas must be able to leave the housing. Due to the vertical installation,
the non-condensable gas is able to leave the housing and flows into the steam/gas chamber above it, which has the same
pressure level. If the self-venting through the pipe must be extended, the control screw (4) can be replaced by a cutting ring
screw bolt and a compensation line can be installed leading upwards.
2.7 Automatic venting
■ In the case of steam applications, automatic venting must be provided (vent jet or capsule venting).
2.8 Gastight under-level float control (only for gas applications)
■ For gas applications, a gastight under-level float control is nearly exclusively used. Consult with Rifox, if necessary.
06/2016 -Di. Subject to modifications

Page 2 of 5

RIFOX - Hans Richter GmbH Spezialarmaturen Fon: +49 (0) 421 499 75 - 0 www.rifox.de [email protected]
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: +49 (0) 421 499 75 - 40 www.rifoxglobal.com [email protected]
 Operating Manual

3 Assembly
The condensate trap has to be screwed into a pipeline between flanges.
■ Remove transport caps from inlet and outlet.
■ Fitting direction: according to Picture 1.
■ Supporting brackets: The supporting brackets are not necessary if the pipeline is adequately supported before and after
the condensate trap. The condensate trap weights from 11,5 kg to 33, depending on the connection sizes.
■ To avoid downtimes, it is recommended to install stop valves with bypass to pipeline, both in front of and behind the con-
densate trap.
4 Start-Up
The pressure build-up and heating-up of the housing should not take place abruptly. If leakage is detected after the first
inspection, the screws (4 / 5 / 6) can be fixed under consideration of the given torque moments, as given in Section 6.5. The
screws can only be tightened on when the housing is unpressurized and at room temperature.
5 Observation and control
The function’s failure can be observed either as condensate blockage or as gas/ steam leakage.
■ Condensate blockage can be determined by a): loosen the control screw (4) for a quarter rotation, while no condensate
leakage should occur; and by b): a surface thermometer on the housing for steam applications (if necessary, please consult
with Rifox).
■ Gas / steam leakage: can be determined by an ultrasonic measuring device, and for steam applications by a surface
thermometer. In case of steam leakage, open the condensate trap according to Section 6.1. Make sure that float (9) can be
easily moved. If necessary, disassemble and clean the float control assembly (7). If damages/ wears are detected on parts or
on the sealing surface, the complete float control assembly (7) should be replaced.
6 Maintenance / Inspection
6.1 Opening the steam trap and dismantling the float control (Picture 4)
■ The steam trap must be depressurized. Shut off the system securely in
front of and behind the steam trap.
■ Release any remaining pressure in the housing by loosening the control
screw (4) by only a quarter turn.
■ Dismantle the steam trap from the pipeline system.
■ Loosen the housing screws (5) evenly crosswise. Put down the housing
cover (1).
■ Screw in the install bolt (Picture 4).
■ With a few light strokes using plastic hammer on the front side of the Plastic Install bolt Housing Float control
install bolt to loosen the float control assembly (7) from the conic housing hammer assembly
seat. Picture 4
■ Screw out the install bolt and take out the float control assembly (7).
6.2 Disassembling, cleaning and assembling the float control (Picture 5)
■ After removing the cotter pin (p), the rotary valve (v) can be simply pulled out b p v
to the side.
■ Clean the parts using, for example, benzine.
■ Check the rotary valve (v) for wear along the sealing edge. If wear is detected,
the support body (b) together with the rotary valve (v) must be replaced. The
thorough leakage test must be carried out by RIFOX.
■ During assembly ensure that the notch in the rotary valve (v) points to the
punch mark on the support body (b) and the cotter pin (p) is inserted and secured
again carefully.
06/2016 -Di. Subject to modifications

■ It must be possible to move the float up and down easily by hand. Picture 5

Page 3 of 5

RIFOX - Hans Richter GmbH Spezialarmaturen Fon: +49 (0) 421 499 75 - 0 www.rifox.de [email protected]
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: +49 (0) 421 499 75 - 40 www.rifoxglobal.com [email protected]
 Operating Manual

6.3 Installation of the float control unit and assemble the steam trap (Picture 6)
■ The complete float control assembly (7) is inserted into the conical housing seat
with the support body. It must be ensured that the tube is positioned vertically down-
wards.
■ Screw in the install bolt in the support body and tighten it with a standard ring
wrench.
■ Loosen the install bolt.
■ Check the housing gasket (2), replace it it is damaged.
■ Put on the housing cover (1).
■ Tighten the housing screws (5) evenly crosswise. Tightening torque according to
Install bolt Housing Tube
Section 6.5. Picture 6
6.4 Care and maintenance
■ In the case of a great risk of dirt accumulation, the housing, when it is depressurized, should be rinsed thoroughly from
time to time. If necessary, the float control assembly (7) should also be checked according to Section 6.2.
■ The dirt, which has been accumulated in the housing, can be removed away by screwing off the screw plug (6).
■ For special applications, it is advisable to install a separate upstream strainer.
■ The float control assembly (7) usually does not to be special maintained. The maintenance depends primarily on the wear
resistance of the valve gasket. See Section 6.1 and 6.2.
6.5 Tightening torque

Tightening Torque (Nm)

Position Part Name DN15, DN20, DN25 DN40, DN50
Cu WE PTFE 1.4571 Cu WE PTFE 1.4571
4 Control Valve 40 35 6 32 40 35 6 32
5 Housing Screw - 40 20 35 - 60 25 55
6 Screw Plug 100 85 14 80 100 85 14 80
10 Control Screw 40 35 6 32 40 35 6 32
optional Screws for Sight Glas 20 20
06/2016 -Di. Subject to modifications

Page 4 of 5

RIFOX - Hans Richter GmbH Spezialarmaturen Fon: +49 (0) 421 499 75 - 0 www.rifox.de [email protected]
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: +49 (0) 421 499 75 - 40 www.rifoxglobal.com [email protected]
 Operating Manual

6.6 Spare parts

Only original spare parts can be used.

12 04
05
01 05
01 12
02 02 10

03
08 08
07 07

03 09 09

11 11 06
06

Picture 7: Model WO-1210 Picture 8: Model EF-1281

Pos. Part Name Material for 1210 / 1281 Material for 1210N / 1281N
01 Housing cover P265GH, P250GH 1.4571
02 Housing gasket Cu or soft iron PTFE or 1.4571
P265GH, P250GH, P235GH TC-1 1.4571
03 Housing
complete with mount for control: SS 1.4541
Locking handle: SS 1.4057/plastic
04 Control valve
Threaded union: SS 1.4104
for DN 15-25 made of 8.8 acc. DIN 939/934 A4-70 acc. to DIN 939/934
05 Set of studs with nuts
for DN 40/50 made of A4-70 acc. DIN 939/934
06 Screw plug G½“ BSP, 5.8 G½, A4, acc. to DIN 910
07 Float control assembly 1.4057 / 1.4112 / 1.4301 /1.4541 (1.4571) 1.4571
08 Supporting body assembly 1.4057 / 1.4301 / 1.4112 / 1.4541 (1.4571) 1.4571
09 Float SS 1.4301 (1.4571) 1.4571
10 Control screw G¼“, SS 1.4104 G¼“, 1.4571
11 Gasket soft iron PTFE or 1.4571

12 Gasket Cu or soft iron PTFE or 1.4571

7 Conformity assessment
The pressure equipment described is a pressure-keeping component in accordance with the
Pressure Vessel Directive 2014/68/EU.
DN15 / DN20 / DN25: according to Art. 4, Subs. 3, no CE-Mark.
DN40 / DN50: Conformity verified through the identifying mark: CE 0525.
A detailed declaration of conformity assessment according to PED is available as separate document. Please request if
necessary, if not attached.
06/2016 -Di. Subject to modifications

Page 5 of 5

RIFOX - Hans Richter GmbH Spezialarmaturen Fon: +49 (0) 421 499 75 - 0 www.rifox.de [email protected]
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: +49 (0) 421 499 75 - 40 www.rifoxglobal.com [email protected]
 Instructions 8471/8472/8473/8477
Industrial, Refrigeration
ECT/ECTR/ECTN

Technical specification
Mounting torque: 15 ... 20 Nm
Operating temperature: – 25°C ... +85°C
Media temperature: ECT: – 25°C ... +125°C
ECT 400bar/5000psi: – 10°C ... +125°C
ECTN: – 25°C ... +85°C
ECTN 400bar/5000psi: – 10°C ... +85°C
Type label description

Measuring range Serial number Type code Manufacturing date Max. overpressure
(W/Y)

Type : 847X.XX.XXXX

H73324k Trafag AG 01/2016

S/N : YYYYYY-ZZZ 16/11
Range : -1...9 bar-G max.: 20 bar
Us : 9...30V DC (2) Us : 4...20mA (1)

Supply positive Supply voltage Pin assignment Output signal

Electrical connections

Ingress IP652) IP67 / IP68 max.3m IP672) IP672) IP65

Protection

EN175301-803A Cable M12x1 Packard Metri Pack Industrial

Designation
(DIN43650-A) (PVC) (PUR) 5–pol. 3–pol. Standard

We reserve the right to make alternations as technical progress may warrant.

4 x 0.25mm2 contact distance
9.4 mm

Type code 847X.XX.XXXX.05 847X.XX.XXXX.22/68 847X.XX.XXXX.35 847X.XX.XXXX.51 847X.XX.XXXX.01

3 2 3 2
3
Pin 5
configuration 2 1

4
1
1

Output Load resistance ISUPPLY USUPPLY

4 ... 20 mA (USUPPLY –9V)/ 20mA 9 ... 30 VDC
0 ... 5 VDC > 2.5 kΩ <10 mA 10 ... 30 VDC
1 ... 6 VDC > 5.0 kΩ <10 mA 10 ... 30 VDC
0 ... 10 VDC > 5.0 kΩ <10 mA 15 ... 30 VDC
0.5 ... 4.5 VDC > 5.0 kΩ <10 mA 5 VDC ±  0.25 V
2)
Provided female connector is mounted according to instructions
Ventilation via cable end/connector. Shield in the device is not connected

www.trafag.com
Electrical connections
36–38 with male thread 36–38 with male thread 19.5
48.5–50.5 with female thread 36-38 with male 10 48.5–50.5 with female
thread thread 1500 15
5

Ø 4.9
Ø 4.5
Ø 21
Ø 29.5
Ø 29.5

SW27
SW27

Ø 27

Ø 34
Ø 27

Ø 34

847X.XX.XXXX.05.XX.XX 847X.XX.XXXX.35.XX.XX 847X.XX.XXXX.22.XX.XX

39 25.5 39 8.5 Pressure connections

G1/4“
Ø22
1
1.4305
Ø 29.5
SW27
1.4305
Ø 29.5
SW27

Ø 27
Ø 29
12.5
Ø 27
Ø 29

847X.XX.XXXX.51.XX.XX 847X.XX.XXXX.01.XX.XX 847X.XX.XX10.XX...

(25)
Pressure connections
12 2 13.5 3 8 15.1 2
14

7/16“-20UNF
Ø20

M5x7
G1/4"

7/16“-20UNF
M5x7

1/4" NPT
O-Ring Seal 1.5
G1/2"

SW27
ø29.5

Ø13.1x1.6 DIN3869
7.5

847X.XX.XX17.XX... 847X.XX.XX18.XX... 847X.XX.XX21.XX... 847X.XX.XX24.XX... 847X.XX.XX30.XX...

11.5 16 31-33 with male thread

Bore
M 2:1 2.7
G3/4"
30°

Ra1.6
Ø 10
G3/4"

G3/4"
R1

16
Ø 23 H8

Ø 23
Ø 27

O-Ring
Ø20x1.5
Ø 34

Ø 50
SW36
Ø 39

16 Sealing DIN/ISO 3869

23.9x29.2x1.5

847X.XX.XX52.XX... Welding flange for G3/4" frontal membrane (1.4301)

Ordering No. C27805
Connection of the measuring equipment
Current output single arrangement multiple arrangement
2-wires Us (pos. Supply)

shield shield shield

Us (neg. Supply)

Voltage output single arrangement multiple arrangement

3-wires Us (pos. Supply)

shield shield shield

Output

www.trafag.com Us (neg. Supply)

 ECTN 8477

Marine Pressure
Transmitter
Swiss based Trafag is a leading international supplier of high quality
sensors and monitoring instruments for measurement of pressure
and temperature. The economic pressure transmitter ECTN 8477 is
based on the tried and true ECT line of transmitters. The wide media
temperature range from -25 to 85°C in combination with a compre-
hensive set of of features and options makes the ECTN 8477 pressure
transmitter a versatile solution suitable for marine applications.

06/2016
Applications Features
NN Shipbuilding NN Economical
NN Engine manufacturing NN Good media compatibility

Data sheet H72322d 

NN Relative or absolute pressure measurement
NN Titanium version optional

Subject to change
Technical Data
Measuring principle Thick film on ceramic Media temperature -25°C ... +85°C
400 bar/5000 psi: -10°C ... +85°C
Measuring range 0 ... 1 to 0 ... 400 bar Ambient temperature -25°C ... +85°C
0 ... 15 to 0 ... 5000 psi
Output signal 4 ... 20 mA Approval DNV, GL, KRS, RINA
Accuracy @ 25°C typ. ± 0.5 % FS typ.

Trafag Sensors & Controls Industriestrasse 11 Tel. +41 44 922 32 32 www.trafag.com

Switzerland 8608 Bubikon Fax +41 44 922 32 33 [email protected]
 ECTN 8477
Ordering information/type code

8477 . XX XX XX XX XX XX
Measuring Pressure
Over Burst
Pressure
Over Burst
measurement measurement
range 1) pressure pressure pressure pressure
range range
[bar] [bar] [psi] [psi]
[bar] [psi]
0 ... 1.0 2 3 71 0 ... 15 30 45 G1
0 ... 1.6 3.2 4.8 73 0 ... 20 40 70 G3
0 ... 2.5 5 7.5 75 0 ... 30 60 90 G5
0 ... 4 8 12 76 0 ... 50 100 150 G6
0 ... 6 12 15 77 0 ... 100 200 250 G7
0 ... 10 20 25 78 0 ... 150 300 375 G8
0 ... 16 32 40 79 0 ... 250 500 625 G9
0 ... 25 50 75 80 0 ... 400 800 1200 H0
0 ... 40 80 100 81 0 ... 500 1000 1250 H1
0 ... 60 120 180 82 0 ... 1000 2000 3000 H2
0 ... 100 4) 200 300 83 0 ... 1500 4) 3000 4500 H3
0 ... 160 4) 320 480 85 0 ... 2000 4) 4000 6000 H5
0 ... 250 4) 500 750 74 0 ... 3000 4) 6000 9000 G4
0 ... 400 2) 4) 800 1000 84 0 ... 5000 2) 4) 10000 12500 H4

Sensor Relative pressure, 1.4404/1.4435 59

Relative pressure, 1.4462 4) 52
Relative pressure, Titanium Grade 5 4) 53
Absolute pressure, 1.4404/1.4435 3) 89
Absolute pressure, 1.4462 3) 4) 82
Absolute pressure, Titanium Grade 5 3) 4) 83

Pressure G1/4" female 4) 10

connection G1/4" male 17
G1/2" male 4) 21
1/4"NPT male 4) 30

Electrical Male electrical plug EN 175301-803-A, Mat. PA 05

connection ​ ​

Output Signal output Load resistance I (supply) U (supply)

4 ... 20 mA (Usupply-9V) / 20mA ​ 9 ... 30 VDC 19

Accessories O-Ring FKM (-20°C ... +125°C) 61

O-Ring EPDM (-25°C ... +125°C) 63
Female electrical connector EN 175301-803-A (DIN43650-A) 58
Pressure peak damping element ø 0.4 mm 44
Pressure peak damping element ø 1.0 mm (for pressure connections 17 and 30) 40
Special electrical connection: Pin 1 + , Pin 2 -
92
(only for output 4...20mA and male electrical plug EN175301-803-A / DIN43650-A)

1)
Extended overpressure as well as customized pressure ranges upon request
2)
Media -10°C ... +85°C
3)
Absolute ranges max. 40 bar
4)
Upon request

H72322d page 2/6

 ECTN 8477
Standard products (extra short lead time)
Product No. Type Code Pressure range Over pressure Signal output Supply
[bar] max. [VDC]
[bar]
ECTN1.0A 8477 71 5917 05 0000 0000 19 58 61 0 ... 1 2 4 ... 20 mA 9 ... 30
ECTN2.5A 8477 75 5917 05 0000 0000 19 58 61 0 ... 2.5 5 4 ... 20 mA 9 ... 30
ECTN4.0A 8477 76 5917 05 0000 0000 19 58 61 0 ... 4 8 4 ... 20 mA 9 ... 30
ECTN6.0A 8477 77 5917 05 0000 0000 19 58 61 0 ... 6 12 4 ... 20 mA 9 ... 30
ECTN10.0A 8477 78 5917 05 0000 0000 19 58 61 0 ... 10 20 4 ... 20 mA 9 ... 30
ECTN16.0A 8477 79 5917 05 0000 0000 19 58 61 0 ... 16 32 4 ... 20 mA 9 ... 30
ECTN25.0A 8477 80 5917 05 0000 0000 19 58 61 0 ... 25 50 4 ... 20 mA 9 ... 30
ECTN40.0A 8477 81 5917 05 0000 0000 19 58 61 0 ... 40 80 4 ... 20 mA 9 ... 30

H72322d page 3/6

 ECTN 8477
Specifications
Accuracy TEB typ. @ -25 ... +85°C ± 3.0 % FS typ.
Accuracy @ 25°C typ. ± 0.5 % FS typ.
NLH @ 25°C (BSL) typ. ± 0.2 % FS typ.
TC zero point and span typ. ± 0.03 % FS/K typ.
Long term stability 1 year typ. ± 0.3 % FS typ.
Electrical Data Output / supply voltage 4 ... 20 mA: 24 (9 ... 30) VDC
Rise time Typ. 1 ms/ 10...90 % Nominal pressure
Switch-on-delay 100 ms
Inverse-polarity protection, short-circuit strenght 4...20 mA: to Us = 30 VDC
@ 25°C during 5 min.
Environmental conditions Media temperature -25°C ... +85°C
400 bar/5000 psi: -10°C ... +85°C
Ambient temperature -25°C ... +85°C
Protection 1)
min. IP65
Humidity Max. 95 % relative
Vibration 20g (10...2000 Hz)
Shock 50g / 3 ms
EMC Protection Emission EN/IEC 61000-6-3
Immunity EN/IEC 61000-6-2
Mechanical Data Sensor Ceramic, Al2O3 (96 %)
Housing / pressure connection 59/89: 1.4404/1.4435 (AISI316L)
52/82: 1.4462 (AISI318LN)
53/83: Titanium Grade 5
Sealing FKM 70 Sh,
EPDM
Male electrical plug See ordering information
Weight ~ 110 g
Mounting torque 15...20 Nm

1)
See electrical connection

Measuring accuracy 0.5 %

8
7
6
5
4
3
2
Accuracy (%)

1
0
-1
-2
-3
-4
-5
-6
-7
-8
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100

max. typ. TEB (-25...+85°C) Temp. (°C)

H72322d page 4/6

 ECTN 8477
Dimensions

36–38 with male thread

48.5–50.5 with female thread
Ø 29.5
SW27
Ø 27

Ø 34

8477.XX.XXXX.05.XX.XX

(25)
12 2 3 8 15.1 2
14
G1/4“
Ø22

M5x7
G1/4"
M5x7

1/4" NPT
1 O-Ring Seal

G1/2"

SW27
ø29.5
12.5 Ø13.1x1.6 DIN3869

8477.XX.XX10.XX.XX.XX 8477.XX.XX17.XX.XX.XX 8477.XX.XX21.XX.XX.XX 8477.XX.XX30.XX.XX.XX

0
5.5 -1 28.5
35.5

1)
M3

1) Tightening torque 50...60Ncm

8477.XX.XXXX.XX.XX.58

H72322d page 5/6

 ECTN 8477
Electrical connection
Protection / electrical connection
IP65*)
Industrial standard
EN175301-803A
05

1 2
3

Standard with accessory 92

Us (pos. Supply) 2 1
P
Output signal

4-20mA Us (neg. Supply) 1 2

I Earth (housing) <e> <e>

Shield*** )

8477.xx.xxxx.xx.19

*) Provided female connector is mounted according to instructions

***) Only cable versions or female plug with shield connection

Additional information
Documents Data sheet www.trafag.com/H72322
Instructions www.trafag.com/H73324
Flyer www.trafag.com/H70688

H72322d page 6/6

 KONFORMITÄTSERKLÄRUNG
DECLARATION OF CONFORMITY
DÉCLARATION DE CONFORMITÉ

Wir / We / Nous
Firma Trafag AG
Industriestrasse 11
CH-8608 Bubikon

erklären in alleiniger Verantwortung, dass das Produkt

declare under our sole responsibility that the product
déclarons sous notre seule responsabilité que la produit

Pressure transmitter
8471/8472/8473/8474/8475/8476/8477
ECT/ECTF/ECTN/ECTR/ECTRV

auf das sich diese Erklärung bezieht, mit den folgenden Normen übereinstimmt
to which this declaration relates is in conformity with the following standards
auquel se réfère cette déclaration est conforme aux normes

EN 61000-6-2
EN 61000-6-3

gemäss den Bestimmungen der Richtlinie

following the provisions of Directive
conformément aux dispositions de Directive

2014/30/EU

Bubikon, April 20, 2016

Dieter Zeisel André Nipkow

Director Development Director Sales

Trafag AG  |  Industriestrasse 11  |  CH-8608 Bubikon  |  Tel +41 44 922 32 32  |  Fax +41 44 922 32 33  |  www.trafag.com
 Electronic
pressure measurement

Electronic pressure switch with display

Model PSD-30, standard version
Model PSD-31, with flush diaphragm
WIKA data sheet PE 81.67

Applications

■■ Machine tools
■■ Hydraulics and pneumatics
■■ Pumps and compressors
■■ Machine building

Special features

■■ Easily readable, robust display

■■ Intuitive and fast setup
■■ Easy and flexible mounting configurations

Electronic pressure switch, model PSD-30

Description
Award-winning in design and functionality Customised installation
The successful design and the excellent functionality of the The installation of the PSD-30 and PSD-31 can be flexibly
WIKA switch family were already confirmed by winning the adapted to the individual mounting situation. Due to the
“iF product design award 2009” for the PSD-30 pressure almost unlimited rotation of the display and case by more
switch. than 300°, the display can be adjusted independently of the
electrical connection. The display can thus always be aligned
The robust LED display has been designed using 9 mm high to face the operator, and the M12 x 1 connection positioned
characters (the largest possible) and with a slight incline in to suit the desired cable routing.
order to make reading the pressure as easy as possible from
a long way off. A 14-segment display has been used, since it High quality
represents text very well. During development of the WIKA switch family a high value
The 3-key operation makes simple, intuitive menu navigation was placed on a robust design and the selection of appropri-
possible, with no need for additional assistance. The menu ate materials suited to machine-building applications. For this
navigation conforms to the latest VDMA standard. reason the case and the threaded connection of the electrical
The VDMA standard for fluid sensors (24574-1, part 1 - connector are made from stainless steel. Overwinding or
pressure switches) has the aim of simplifying the use of tearing off the connector is therefore virtually impossible.
pressure switches by standardising menu navigation and
display. IO-Link
The control keys have been designed as large as possible With the optional output signal in accordance with the IO-Link
and are arranged ergonomically to ensure fast and easy communication standard, the PSD-30 and PSD-31 allow a
adjustments. Operation without any additional assistance is fast integration into modern automation systems. IO-Link
made easier through the tactile feedback. offers an even faster installation, parameterisation and higher
functionality of the PSD-30 and PSD-31.

WIKA data sheet PE 81.67 ∙ 04/2015 Page 1 of 8

Data sheets showing similar products:

Electronic temperature switch with display; model TSD-30; see data sheet TE 67.03
Electronic level switch with display; model LSD-30; see data sheet LM 40.01
Measuring ranges
Gauge pressure
bar 0 ... 1 1) 0 ... 1.6 1) 0 ... 2.5 0 ... 4 0 ... 6 0 ... 10 0 ... 16 0 ... 25
0 ... 40 0 ... 60 0 ... 100 0 ... 160 0 ... 250 0 ... 400 0 ... 600
psi 0 ... 15 1) 0 ... 25 1) 0 ... 30 1) 0 ... 50 0 ... 100 0 ... 160 0 ... 200 0 ... 300
0 ... 500 0 ... 1,000 0 ... 1,500 0 ... 2,000 0 ... 3,000 0 ... 5,000 0 ... 8,000

Absolute pressure
bar 0 ... 1 1) 0 ... 1.6 1) 0 ... 2.5 0 ... 4 0 ... 6 0 ... 10 0 ... 16 0 ... 25
psi 0 ... 15 1)
0 ... 25 1) 0 ... 30 1) 0 ... 50 0 ... 100 0 ... 160 0 ... 200 0 ... 300

Vacuum and +/- measuring range

bar -1 ... 0 1) -1 ... +0.6 1) -1 ... +1.5 -1 ... +3 -1 ... +5 -1 ... +9 -1 ... +15 -1 ... +24
psi -14.5 ... 0 1)
-14.5 ... +15 1)
-14.5 ... +30 -14.5 ... +50 -14.5 ... +100 -14.5 ... +160 -14.5 ... +200 -14.5 ... +300
1) Not available for PSD-31.

Overpressure limit
2 times
1.7 times for the relative pressure measuring ranges 160 psi,
1,000 psi and 1,500 psi

Display

14-segment LED, red, 4-digit, 9 mm (0.35 inch) character size

Display can be turned electronically through 180°
Update (adjustable): 100, 200, 500 or 1,000 ms

Output signals

Switching output Analogue signal Switching voltage

SP1 SP2 Power supply - 1 V
PNP - 4 ... 20 mA (3-wire)
PNP - DC 0 ... 10 V (3-wire)
Switching current
PNP PNP - ■■ without IO-Link: max. 250 mA
PNP PNP 4 ... 20 mA (3-wire) ■■ with IO-Link: SP1 max. 100 mA
PNP PNP DC 0 ... 10 V (3-wire) SP2 max. 250 mA

Optionally also available with an NPN instead of a PNP Settling time

switching output
Analogue signal: 3 ms
Switching output: ≤ 10 ms (20 ms with IO-Link)
IO-Link, revision 1.1 (option)
IO-Link is optionally available for all output signals. Load
With the IO-Link option, switching output SP1 is always PNP
Analogue signal 4 ... 20 mA: ≤ 0.5 kΩ
Analogue signal DC 0 ... 10 V: > 10 kΩ
Zero offset adjustment
max. 3 % of span Service life
100 million switching cycles
Switching thresholds
Switch point 1 and switch point 2 are individually adjustable

Switching functions
Normally open, normally closed, window, hysteresis
Freely adjustable

Page 2 of 8 WIKA data sheet PE 81.67 ∙ 04/2015

Voltage supply Operating conditions

Power supply Permissible temperature ranges

DC 15 ... 35 V Medium: -20 ... +85 °C (-4 ... +185 °F)
Ambient: -20 ... +80 °C (-4 ... +176 °F)
Current consumption Storage: -20 ... +80 °C (-4 ... +176 °F)
Switching outputs with Nominal temperature: 0 ... 80 °C (32 ... 176 °F)
■■ Analogue signal 4 ... 20 mA: 70 mA
■■ Analogue signal DC 0 ... 10 V: 45 mA Humidity
■■ without analogue signal: 45 mA 45 ... 75 % r. h.

IO-Link option causes a deviating current consumption Vibration resistance

10 g (IEC 60068-2-6, under resonance)
Total current consumption
■■ without IO-Link: max. 600 mA including switching current Shock resistance
■■ with IO-Link: max. 450 mA including switching current 50 g (IEC 60068-2-27, mechanical)

Service life, mechanics

100 million load cycles (10 million load cycles for measuring
Accuracy specifications ranges > 600 bar/7,500 psi)

Accuracy, analogue signal Ingress protection

≤ ±1.0 % of span IP 65 and IP 67

Including non-linearity, hysteresis, zero offset and end value  he stated ingress protection (per IEC 60529) only applies
T
deviation (corresponds to measured error per IEC 61298-2). when plugged in using mating connectors that have the
Calibrated in vertical mounting position with process connec- appropriate ingress protection.
tion facing downwards.
Mounting position
Non-linearity: ≤ ±0.5 % of span (BFSL, IEC 61298-2)
as required
Long-term drift: ≤ ±0.2 % of span (IEC 61298-2)

Accuracy, switching output

Switch point accuracy: ≤ ±1 % of span
Adjustment accuracy: ≤ ±0.5 % of span

Display
≤ ±1.0 % of span ± 1 digit

Temperature error in rated temperature range

■■ typical: ≤ ±1.0 % of span
■■ maximum: ≤ ±2.5 % of span

Temperature coefficients in rated temperature range

Mean TC zero point: ≤ ± 0.2 % of span/10 K (typical)
Mean TC span: ≤ ± 0.1 % of span/10 K (typical)

Reference conditions
Temperature: 15 ... 25 °C (59 ... 77 °F)
Atmospheric pressure: 950 ... 1,050 mbar (13.78 ... 15.23 psi)
Humidity: 45 ... 75 % r. h.
Nominal position: Process connection lower mount (LM)
Power supply: DC 24 V
Load: see output signals

WIKA data sheet PE 81.67 ∙ 04/2015 Page 3 of 8

Materials

Wetted parts
Process connection: Stainless steel 316L
Pressure sensor: < 9.8 bar: Stainless steel 316L
≥ 9.8 bar: Stainless steel 13-8 PH

Non-wetted parts
Case: Stainless steel 304
Keyboard: TPE-E
Display window: PC
Display head: PC+ABS-Blend

Options for specific media

Medium Option
Oil and grease free Residual hydrocarbon: < 1,000 mg/m2
Oxygen, oil and grease ■■ Residual hydrocarbon: < 200 mg/m2
free ■■ Packaging: Protection cap on the process connection
■■ Maximum permissible temperature -20 ... +60 °C (-4 ... +140 °F)
■■ Only available for PSD-30
■■ Available measuring ranges:
- 0 ... 10 to 0 ... 400 bar gauge
- -1 ... 9 to -1 ... 24 bar
■■ Factory supplied without sealing

Process connections

Available connections, model PSD-30 Sealings

Standard Thread Process connection per DIN 3852-E

DIN 3852-E G¼A Standard NBR
G½A Option 1 without
EN 837 G¼B Option 2 FPM/FKM
G ¼ female
G½B
Process connection per EN 837 1)
ANSI/ASME B1.20.1 ¼ NPT
½ NPT Standard without
ISO 7 R¼ Option 1 Copper
KS PT ¼ Option 2 Stainless steel
- G ¼ female (Ermeto compatible) 1) Process connections per EN 837 with female threads do not include any seal.

Other connections on request.

Process connection G ½ B flush
Available connections, model PSD-31 Standard NBR
Option FPM/FKM
Standard Thread
- G ½ B with flush diaphragm

Page 4 of 8 WIKA data sheet PE 81.67 ∙ 04/2015

Electrical connections CE conformity

Connections Pressure equipment directive

■■ Circular connector M12 x 1 (4-pin) 97/23/EC
■■ Circular connector M12 x 1 (5-pin) 1)
1) Only for version with two switching outputs and additional analogue signal EMC directive
2004/108/EC, EN 61326 emission (group 1, class B) and
Electrical safety interference immunity (industrial application)
Short-circuit resistance: S+ / SP1 / SP2 vs. U-
Reverse polarity protection: U+ vs. U-
Insulation voltage: DC 500 V Manufacturer's declaration
Overvoltage protection: DC 40 V
RoHS conformity
Connection diagram 2011/65/EU

Circular connector M12 x 1 (4-pin)

U+ 1 Approvals
U- 3
4 3
S+ 2 ■■ cULus, safety (e.g. electr. safety, overpressure, ...), USA,
1 2 SP1/C 4
Canada
■■ EAC, import certificate, customs union Russia/Belarus/
SP2 2
Kazakhstan
■■ CRN, safety (e.g. electr. safety, overpressure, ...), Canada
Circular connector M12 x 1 (5-pin)
U+ 1 Approvals and certificates, see website
U- 3
S+ 5
SP1/C 4
SP2 2

Legend:
U+ Positive power supply
U- Reference potential
SP1 Switching output 1
SP2 Switching output 2
C Communication with IO-Link
S+ Analogue output

WIKA data sheet PE 81.67 ∙ 04/2015 Page 5 of 8

Dimensions in mm (inch)

Pressure switch with circular connector M12 x 1 (4-pin and 5-pin)

(∅1.50) (∅1.16)

(1.42)

(2.83)
(1.02)
(∅1.38)

(1.06)

(0.79)

Weight: approx. 220 g (7.76 oz)

Process connections, model PSD-30

G L1 G L1 G L1
G ¼ A DIN 3852-E 12 (0.47) G ¼ B EN 837 13 (0.51) ¼ NPT 13 (0.51)
G ½ A DIN 3852-E 14 (0.55) G ½ B EN 837 20 (0.79) ½ NPT 19 (0.75)
R¼ 13 (0.51)
PT ¼ 13 (0.51)

Process connections, model Process connection, model PSD-31

PSD-30
Female thread Female thread Flush

G L1 L2 L3 D1 G L1 L2 L3 D1 G L1 L2 L3 D1
G¼ 1)
20 15 12 ∅ 25 G ¼ EN 837 20 13 10 ∅ 25 G½B 2)
23 20.5 10 ∅ 18
(0.79) (0.59) (0.47) (∅ 0.98) (0.79) (0.51) (0.39) (∅ 0.98) (0.91) (0.81) (0.39) (∅ 0.71)
1) Ermeto compatible
2) Welding sockets recommended as defined counter-thread (see accessories)

Page 6 of 8 WIKA data sheet PE 81.67 ∙ 04/2015

Accessories and spare parts
Welding socket
Description Order no.
G ½ B female, outer diameter 50 mm (2 in), material 1.4571 1192299

Sealings
Description Order no.
NBR profile sealing G ¼ A DIN 3852-E 1537857
FPM/FKM profile sealing G ¼ A DIN 3852-E 1576534
NBR profile sealing G ½ A DIN 3852-E 1039067
FPM/FKM profile sealing G ½ A DIN 3852-E 1039075
Copper G ¼ B EN 837 11250810
Stainless steel G ¼ B EN 837 11250844
Copper G ½ B EN 837 11250861
Stainless steel G ½ B EN 837 11251042

Connectors with moulded cable

Description Temperature range Cable diameter Order no.
Straight version, cut to length, 4-pin, 2 m (6.6 ft) -20 ... +80 °C 4.5 mm 14086880
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.18 in)
Straight version, cut to length, 4-pin, 5 m (16.4 ft) -20 ... +80 °C 4.5 mm 14086883
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.18 in)
Straight version, cut to length, 4-pin, 10 m (32.8 ft) -20 ... +80 °C 4.5 mm 14086884
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.18 in)
Straight version, cut to length, 5-pin, 2 m (6.6 ft) -20 ... +80 °C 5.5 mm 14086886
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.22 in)
Straight version, cut to length, 5-pin, 5 m (16.4 ft) -20 ... +80 °C 5.5 mm 14086887
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.22 in)
Straight version, cut to length, 5-pin, 10 m (32.8 ft) -20 ... +80 °C 5.5 mm 14086888
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.22 in)
Angled version, cut to length, 4-pin, 2 m (6.6 ft) -20 ... +80 °C 4.5 mm 14086889
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.18 in)
Angled version, cut to length, 4-pin, 5 m (16.4 ft) -20 ... +80 °C 4.5 mm 14086891
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.18 in)
Angled version, cut to length, 4-pin, 10 m (32.8 ft) -20 ... +80 °C 4.5 mm 14086892
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.18 in)
Angled version, cut to length, 5-pin, 2 m (6.6 ft) -20 ... +80 °C 5.5 mm 14086893
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.22 in)
Angled version, cut to length, 5-pin, 5 m (16.4 ft) -20 ... +80 °C 5.5 mm 14086894
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.22 in)
Angled version, cut to length, 5-pin, 10 m (32.8 ft) -20 ... +80 °C 5.5 mm 14086896
PUR cable, UL listed, IP 67 (-4 ... 176 °F) (0.22 in)

Cooling element for screwing G ½ female / G ½ male

(for instruments with process connection G ½ B)
Description Order no.
Max. medium temperature 150 °C (302 °F) at an ambient temperature of max. 30 °C (86 °F) 14055439
Max. operating pressure 250 bar (3,626 psi)

Max. medium temperature 200 °C (392 °F) at an ambient temperature of max. 30 °C (86 °F) 14055438
Max. operating pressure 250 bar (3,626 psi)

WIKA data sheet PE 81.67 ∙ 04/2015 Page 7 of 8

 Instrument mounting bracket
Description Order no.
Instrument mounting bracket for PSD-30, aluminium, wall mounting 11467887

Ordering information
Model / Measuring range / Output signal / Process connection / Accessories and spare parts
© 2011 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.

Page 8 of 8 WIKA data sheet PE 81.67 ∙ 04/2015

04/2015 EN

WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. +49 9372 132-0
Fax +49 9372 132-406
[email protected]
www.wika.de
 Operating instructions
Betriebsanleitung
Mode d'emploi
Manual de instrucciones

Pressure switch model PSD-3x EN

Druckschalter Typ PSD-3x DE

Pressostat type PSD-3x FR

Presostato modelo PSD-3x ES

Pressure switch model PSD-30

EN Operating instructions model PSD-3x Page 3 - 32
DE Betriebsanleitung Typ PSD-3x Seite 33 - 62
FR Mode d'emploi type PSD-3x Page 63 - 92
ES Manual de instrucciones modelo PSD-3x Página 93 - 122

© 2010 WIKA Alexander Wiegand SE & Co. KG

All rights reserved. / Alle Rechte vorbehalten.
WIKA® is a registered trademark in various countries.
WIKA® ist eine geschützte Marke in verschiedenen Ländern.

Prior to starting any work, read the operating instructions!

Keep for later use!

11430486.07 04/2015 EN/DE/FR/ES

Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!

Lire le mode d'emploi avant de commencer toute opération !

A conserver pour une utilisation ultérieure !

¡Leer el manual de instrucciones antes de comenzar cualquier trabajo!

¡Guardar el manual para una eventual consulta posterior!

2 WIKA operating instructions pressure switch, model PSD-3x

 Contents

Contents
EN

1. General information 4
2. Safety 6
3. Specifications 9
4. Design and function 18
5. Transport, packaging and storage 18
6. Commissioning, operation 19
7. Maintenance and cleaning 28
8. Faults 29
9. Dismounting, return and disposal 31
11430486.07 04/2015 EN/DE/FR/ES

Appendix 1: EC Declaration of Conformity for model PSD-3x 32

Declarations of conformity can be found online at www.wika.com.

WIKA operating instructions pressure switch, model PSD-3x 3

 1. General information
1. General information
■■ The pressure switch described in the operating instructions has been designed and manufactured
EN using state-of-the-art technology. All components are subject to stringent quality and environmental
criteria during production. Our management systems are certified to ISO 9001 and ISO 14001.
■■ These operating instructions contain important information on handling the instrument. Working
safely requires that all safety instructions and work instructions are observed.
■■ Observe the relevant local accident prevention regulations and general safety regulations for the
instrument's range of use.
■■ The operating instructions are part of the product and must be kept in the immediate vicinity of the
instrument and readily accessible to skilled personnel at any time.
■■ Skilled personnel must have carefully read and understood the operating instructions, prior to
beginning any work.
■■ The manufacturer's liability is void in the case of any damage caused by using the product contrary
to its intended use, non-compliance with these operating instructions, assignment of insufficiently
qualified skilled personnel or unauthorised modifications to the instrument.
■■ The general terms and conditions contained in the sales documentation shall apply.

■■ Subject to technical modifications.

■■ Further information:

11430486.07 04/2015 EN/DE/FR/ES

- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: PE 81.67
- Application consultant: Tel.: (+49) 9372/132-8976
E-mail: [email protected]

4 WIKA operating instructions pressure switch, model PSD-3x

 1. General information
Explanation of symbols

WARNING!
... indicates a potentially dangerous situation which can result in serious injury or death if not EN
avoided.

CAUTION!
... indicates a potentially dangerous situation which can result in light injuries or damage to
the equipment or the environment if not avoided.

Information
… points out useful tips, recommendations and information for efficient and trouble-free
operation.

Abbreviations
U+ Positive power terminal
U- Negative power terminal
S+ Analogue output
SP1 Switch point 1
SP2 Switch point 2
C Communication with IO-Link
MBA Start of measuring range
11430486.07 04/2015 EN/DE/FR/ES

MBE End of measuring range

WIKA operating instructions pressure switch, model PSD-3x 5

 2. Safety
2. Safety
WARNING!
EN Before installation, commissioning and operation, ensure that the appropriate pressure
switch has been selected in terms of measuring range, design and specific measuring
conditions.
Non-observance can result in serious injury and/or damage to the equipment.

WARNING!
■■ Open the connections only after the system has been depressurised.
■■ Observe the working conditions in accordance with Chapter 3 "Specifications".
■■ Always operate the pressure switch within the overpressure safety range.

Further important safety instructions can be found in the individual chapters of these
operating instructions.

2.1 Intended use

The pressure switch is used to convert pressure into an electrical signal indoors and outdoors.

The instrument has been designed and built solely for the intended use described here, and may only
be used accordingly.

The technical specifications contained in these operating instructions must be observed. Improper

11430486.07 04/2015 EN/DE/FR/ES

handling or operation of the instrument outside of its technical specifications requires the instrument to
be taken out of service immediately and inspected by an authorised WIKA service engineer.

The manufacturer shall not be liable for claims of any type based on operation contrary to the intended
use.

6 WIKA operating instructions pressure switch, model PSD-3x

 2. Safety
2.2 Personnel qualification

WARNING!
Risk of injury if qualification is insufficient!
Improper handling can result in considerable injury and damage to equipment. EN
The activities described in these operating instructions may only be carried out by skilled
personnel who have the qualifications described below.

Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training, knowledge
of measurement and control technology and on their experience and knowledge of country-specific
regulations, current standards and directives, are capable of carrying out the work described and
independently recognising potential hazards.

Special operating conditions require further appropriate knowledge, e.g. of aggressive media.

2.3 Special hazards

WARNING!
For hazardous media such as oxygen, acetylene, flammable or toxic gases or liquids,
and refrigeration plants, compressors, etc., in addition to all standard regulations, the
appropriate existing codes or regulations must also be followed.

WARNING!
Residual media in dismounted pressure switches can result in a risk to persons, the
11430486.07 04/2015 EN/DE/FR/ES

environment and equipment.

Take sufficient precautionary measures.

WIKA operating instructions pressure switch, model PSD-3x 7

 2. Safety
2.4 Labelling / safety marks

Product label
EN Power supply

Measuring range

P# Product No.
S# Serial No.
Analogue signal Switching output 1 Switching output 2

If the serial number becomes illegible (e.g. due to mechanical damage or overpainting), traceability will
no longer be possible.

Explanation of symbols

General danger symbol

cULus, Underwriters Laboratories Inc.®

11430486.07 04/2015 EN/DE/FR/ES

The instrument was inspected in accordance with the applicable US standards and certified
by UL.
Furthermore, instruments bearing this mark comply with the applicable Canadian
standards on safety.

CE, Communauté Européenne

Instruments bearing this mark comply with the relevant European directives.

8 WIKA operating instructions pressure switch, model PSD-3x

 3. Specifications
3. Specifications
3.1 Measuring ranges

Gauge pressure EN
bar 0 ... 1 1) 0 ... 1.6 1) 0 ... 2.5 0 ... 4 0 ... 6 0 ... 10 0 ... 16 0 ... 25
0 ... 40 0 ... 60 0 ... 100 0 ... 160 0 ... 250 0 ... 400 0 ... 600
psi 0 ... 15 1) 0 ... 25 1) 0 ... 301) 0 ... 50 0 ... 100 0 ... 160 0 ... 200 0 ... 300
0 ... 500 0 ... 1,000 0 ... 1,500 0 ... 2,000 0 ... 3,000 0 ... 5,000 0 ... 8,000

Absolute pressure
bar 0 ... 1 1) 0 ... 1.6 1) 0 ... 2.5 0 ... 4 0 ... 6 0 ... 10 0 ... 16 0 ... 25
psi 0 ... 15 1) 0 ... 25 1) 0 ... 30 1) 0 ... 50 0 ... 100 0 ... 160 0 ... 200 0 ... 300

Vacuum and +/- measuring range

bar -1 ... 0 1) -1 ... 0.6 1) -1 ... 1.5 -1 ... 3 -1 ... 5 -1 ... 9 -1 ... 15 -1 ... 24
psi -14.5 ... 0 -14.5 ... 15 -14.5 ... 30 -14.5 ... 50 -14.5 ... 100 -14.5 ... 160 -14.5 ... 200 -14.5 ... 300
The given measuring ranges are also available in kg/cm2 and MPa.

1) Not available for PSD-31.

Overpressure limit
2 times
1.7 times for the relative pressure measuring ranges 160 psi, 1,000 psi and 1,500 psi
11430486.07 04/2015 EN/DE/FR/ES

3.2 Display

14-segment LED, red, 4-digit, 9 mm character size

Display can be turned electronically through 180°
Update (adjustable): 100, 200, 500, 1,000 ms

WIKA operating instructions pressure switch, model PSD-3x 9

 3. Specifications
3.3 Output signals

Switching output 1 Switching output 2 Analogue signal

EN PNP - 4 ... 20 mA (3-wire)
PNP - DC 0 ... 10 V (3-wire)
PNP PNP -
PNP PNP 4 ... 20 mA (3-wire)
PNP PNP DC 0 ... 10 V (3-wire)

Alternatively also available with an NPN instead of a PNP switching output.

With the IO-Link option, switching output 1 is always PNP.

IO-Link, revision 1.1 (option)

IO-Link is optionally available for all output signals.
With the IO-Link option, switching output SP1 is always PNP.

Zero offset adjustment

maximum 3 % of span

Switching thresholds
Switch point 1 and switch point 2 are individually adjustable

Switching functions
Normally open, normally closed, window, hysteresis

11430486.07 04/2015 EN/DE/FR/ES

Freely adjustable

Switching voltage
Power supply - 1 V

10 WIKA operating instructions pressure switch, model PSD-3x

 3. Specifications
Switching current
■■ without IO-Link: max. 250 mA
■■ with IO-Link: SP1 max. 100 mA, SP2 max. 250 mA
EN
Settling time
Analogue signal: 3 ms
Switching output: ≤ 10 ms (20 ms with IO-Link)

Load
Analogue signal 4 ... 20 mA: ≤ 0.5 kΩ
Analogue signal DC 0 ... 10 V: > 10 kΩ

Service life
100 million switching cycles

3.4 Voltage supply

Power supply
DC 15 ... 35 V

Current consumption
Switching outputs with
■■ Analogue signal 4 ... 20 mA: 70 mA
■■ Analogue signal DC 0 ... 10 V: 45 mA
11430486.07 04/2015 EN/DE/FR/ES

■■ without analogue signal: 45 mA

IO-Link option causes a deviating current consumption

Total current consumption

■■ without IO-Link: max. 600 mA including switching current
■■ with IO-Link: max. 450 mA including switching current

WIKA operating instructions pressure switch, model PSD-3x 11

 3. Specifications
3.5 Accuracy data

Accuracy, analogue signal

EN ≤ ±1.0 % of span

Including non-linearity, hysteresis, zero offset and end value deviation (corresponds to measured error
per IEC 61298-2). Calibrated in vertical mounting position with process connection facing downwards.
Non-linearity: ≤ ±0.5 % of span (BFSL, IEC 61298-2)
Long-term drift:≤ ±0.2 % of span (IEC 61298-2)

Accuracy, switching output

Switch point accuracy: ≤ ±1 % of span
Adjustment accuracy: ≤ ±0.5 % of span

Display
≤ ±1.0 % of span ± 1 digit

Temperature error in rated temperature range

■■ typical: ≤ ±1.0 % of span
■■ maximum: ≤ ±2.5 % of span

Temperature coefficients in rated temperature range

Mean TC zero point: ≤ ±0.2 % of span/10 K (typical)
Mean TC span: ≤ ±0.1 % of span/10 K (typical)

11430486.07 04/2015 EN/DE/FR/ES

3.6 Reference conditions
Temperature: 15 ... 25 °C (59 ... 77 °F)
Atmospheric pressure: 950 ... 1,050 mbar (13.78 ... 15.23 psi)
Humidity: 45 ... 75 % r. h.
Nominal position: Process connection lower mount (LM)
Power supply: DC 24 V
Load: see output signals

12 WIKA operating instructions pressure switch, model PSD-3x

 3. Specifications
3.7 Operating conditions

Permissible temperature ranges

Medium: -20 ... +85 °C (-4 ... +185 °F) EN
Ambient: -20 ... +80 °C (-4 ... +176 °F)
Storage: -20 ... +80 °C (-4 ... +176 °F)
Nominal temperature: 0 ... 80 °C (32 ... 176 °F)

Humidity
45 ... 75 % r. h.

Vibration resistance
10 g (IEC 60068-2-6, under resonance)

Shock resistance
50 g (IEC 60068-2-27, mechanical)

Service life, mechanics

100 million load cycles (10 million load cycles for measuring ranges > 600 bar/7,500 psi)

Ingress protection
IP 65 and IP 67
The stated ingress protection (per IEC 60529) only applies when plugged in using mating connectors
that have the appropriate ingress protection.
11430486.07 04/2015 EN/DE/FR/ES

Mounting position
as required

WIKA operating instructions pressure switch, model PSD-3x 13

 3. Specifications
3.8 Materials

Wetted parts
EN Process connection: Stainless steel 316L
Pressure sensor: < 9.8 bar: Stainless steel 316L
≥ 9.8 bar: Stainless steel 13-8 PH

Non-wetted parts
Case: Stainless steel 304
Keyboard: TPE-E
Display window: PC
Display head: PC+ABS-Blend

Options for specific media

Medium Option
Oil and grease free Residual hydrocarbon: < 1,000 mg/m2
Oxygen, oil and grease free ■■ Residual hydrocarbon: < 200 mg/m2
■■ Packaging: Protection cap on the process connection
■■ Maximum permissible temperature -20 ... +60 °C (-4 ... +140 °F)
■■ Only available for PSD-30
■■ Available measuring ranges:
- 0 ... 10 to 0 ... 400 bar gauge
- -1 ... 9 to -1 ... 24 bar
■■ Factory supplied without sealing

11430486.07 04/2015 EN/DE/FR/ES

14 WIKA operating instructions pressure switch, model PSD-3x
 3. Specifications
3.9 Process connections

Available connections, model PSD-30

EN
Standard Thread
DIN 3852-E G¼A
G½A
EN 837 G¼B
G ¼ female
G½B
ANSI / ASME B1.20.1 ¼ NPT
½ NPT
ISO 7 R¼
KS PT ¼
- G ¼ female (Ermeto compatible)

Other connections on request.

Available connections, model PSD-31

Standard Thread
- G ½ B with flush diaphragm
11430486.07 04/2015 EN/DE/FR/ES

WIKA operating instructions pressure switch, model PSD-3x 15

 3. Specifications
Sealings

Process connection per DIN 3852-E

EN Standard NBR
Option 1 without
Option 2 FPM/FKM

Process connection per EN 837 1)

Standard without
Option 1 Copper
Option 2 Stainless steel
1) Process connections per EN 837 with female threads do not include any seal.

Process connection G ½ B flush

Standard NBR
Option FPM/FKM

3.10 Electrical connections

Connections
Circular connector M12 x 1 (4-pin)

11430486.07 04/2015 EN/DE/FR/ES

Circular connector M12 x 1 (5-pin) 1)
1) Only for version with two switching outputs and additional analogue signal

Electrical safety
Short-circuit resistance: S+ / SP1 / SP2 vs. U-
Reverse polarity protection: U+ vs. U-
Insulation voltage: DC 500 V
Overvoltage protection: DC 40 V

16 WIKA operating instructions pressure switch, model PSD-3x

 3. Specifications
3.11 CE conformity

Pressure equipment directive

97/23/EC EN
EMC directive
2004/108/EC, EN 61326 emission (group 1, class B) and interference immunity (industrial application)

3.12 Manufacturer's declaration

RoHS conformity
2011/65/EU

3.13 Approvals

■■ cULus, safety (e.g. electr. safety, overpressure, ...), USA, Canada

■■ EAC, import certificate, customs union Russia/Belarus/Kazakhstan
■■ CRN, safety (e.g. electr. safety, overpressure, ...), Canada

Approvals and certificates, see website

11430486.07 04/2015 EN/DE/FR/ES

For special model numbers, e.g. PSD-30000, please note the specifications stated on the delivery note.

For further specifications see WIKA data sheet PE 81.67 and the order documentation.

WIKA operating instructions pressure switch, model PSD-3x 17

 4. Design and function / 5. Transport, packaging and storage

4. Design and function

4.1 Description
EN By means of a sensor element and by supplying power, the prevailing pressure is converted into a
switching signal or an amplified standardised electrical signal via the deformation of a diaphragm. This
electrical signal varies in proportion to the pressure and can be evaluated accordingly.

PSD-30: Process connection with internal diaphragm (standard version).

PSD-31: Process connection with flush diaphragm for highly viscous or crystallising media that may clog
the bore of the process connection.

4.2 Scope of delivery

Cross-check the scope of delivery with the delivery note.
For flush design (model PSD-31) with pre-mounted sealings and protection cap.

5. Transport, packaging and storage

For the protection of the diaphragm, the flush design (model PSD-31) is delivered with a
special protection cap.
■■ In order to avoid damage at the diaphragm and/or the process connection thread,
remove the protection cap by hand only just before installation.
■■ Keep the protection cap for subsequent storage or transport.

11430486.07 04/2015 EN/DE/FR/ES

■■ Fit the protection cap before dismounting and transporting the instrument.

5.1 Transport
Check the instrument for any damage that may have been caused by transport. With flush design
(model PSD-31), additionally check the diaphragm for any optical damage.
Obvious damage must be reported immediately.

18 WIKA operating instructions pressure switch, model PSD-3x

 5. Transport, packaging and storage / 6. Commissioning, ...
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in installation
site, sending for repair). EN
5.3 Storage
Permissible conditions at the place of storage:
■■ Storage temperature: -20 ... +80 °C
■■ Humidity: 45 ... 75 % relative humidity (no condensation)

In order to protect the diaphragm, mount the protection cap before storing the instrument.

WARNING!
Before storing the instrument (following operation), remove any residual media. This is of
particular importance if the medium is hazardous to health, e.g. caustic, toxic, carcinogenic,
radioactive, etc..

6. Commissioning, operation
CAUTION!
Only use the pressure switch if it is in perfect condition with respect to safety.
Check the following points before commissioning:
■■ Check the diaphragm for any visible damage, since this is a safety-relevant component.
11430486.07 04/2015 EN/DE/FR/ES

■■ Leaking fluid is indicative of damage.

Required tool: SW 27 open-ended spanner, screwdriver

WIKA operating instructions pressure switch, model PSD-3x 19

 6. Commissioning, operation
6.1 Making the mechanical connection
■■ With flush process connections (model PSD-31), remove the protection
cap not until shortly before mounting. During installation, ensure that the
EN diaphragm is not damaged.
■■ The sealing faces at the instrument always have to be clean.
■■ Only ever screw in, or unscrew, the instrument via the spanner flats.
Never use the case as a working surface.
■■ The correct torque depends on the dimensions of the pressure connec-
tion and the gasket used (form/material).
■■ When screwing in, do not cross the threads.
■■ For information on tapped holes and welding sockets, see Technical
Information IN 00.14 at www.wika.de.

Seal

Parallel threads Tapered threads

per EN 837 per DIN 3852-E NPT, R and PT

11430486.07 04/2015 EN/DE/FR/ES

Correct sealing of the process connections with parallel threads at the sealing face  must be made
using suitable flat gaskets, sealing rings or WIKA profile sealings.
The sealing of tapered threads (e.g. NPT threads) is made by providing the thread with additional
sealing material such as, for example, PTFE tape (EN 837-2).

For further information on seals see WIKA data sheet AC 09.08 or under www.wika.com.

20 WIKA operating instructions pressure switch, model PSD-3x

 6. Commissioning, operation
6.2 Making the electrical connection
■■ The instrument must be earthed via the process connection!
■■ The power supply for the pressure switch must be made via an energy-limited electrical circuit in
accordance with section 9.3 of UL/EN/IEC 61010-1 or an LPS to UL/EN/IEC 60950-1 or class 2 in EN
accordance with UL1310/UL1585 (NEC or CEC). The power supply must be suitable for operation
above 2,000 m should the pressure switch be used at this altitude.
■■ For cable outlets, make sure that no moisture enters at the cable end.

Connection diagrams
Circular connector M12 x 1; 4-pin Circular connector M12 x 1; 5-pin

Assignment Assignment
U+ U- S+ SP1 / C SP2 U+ U- S+ SP1 / C SP2
1 3 2 4 2 1 3 5 4 2

Zero point adjustment

Check the indicated zero point on the display during commissioning.
Should an offset be displayed as a result of installation, this can be reset in programming mode with the
11430486.07 04/2015 EN/DE/FR/ES

0SET parameter

■■ Carry out zero point adjustment for relative and vacuum pressure measuring ranges in a
depressurised state.
■■ Carry out zero point adjustment of absolute pressure ranges from 0 bar absolute
(vacuum). Since appropriate references are required for this, we recommend that this is
only carried out by the manufacturer.

WIKA operating instructions pressure switch, model PSD-3x 21

 6. Commissioning, operation
6.3 Operating modes

System start
EN ■■ Display is fully activated for 2 sec.
■■ When the pressure switch is powered up within the range of the hysteresis, the output switch is set to
"not active" by default.

Display mode
Normal operation, display pressure value

Programming mode
Setting the parameters

6.4 Keys and functions

The pressure switch has two operating modes, the display mode and the programming mode. The
selected operating mode determines the respective function of the key.

Jumping into the programming mode

Keep the "MENU" key pressed for approx. 5 seconds. If the password is set to ≠
0000, a password will be requested. If authentication is successful, then it enters
the programming mode, otherwise it reverts to display mode.

Returning to the display mode

11430486.07 04/2015 EN/DE/FR/ES

Simultaneous pressing of both keys.

22 WIKA operating instructions pressure switch, model PSD-3x

 6. Commissioning, operation
Status switching output 2 (optional) 4-digit LED display
■■ Display pressure value
■■ Display menu item
Status switching output 1 ■■ Display parameter
EN

Display mode Display mode

▶ Short press ▶ Short press
Display of the unit Display of the unit

▶ Long press ▶ Long press

Display of the set parameters see chapter Jumping into the programming mode
6.4 "Parameters"
Programming mode
Programming mode ▶ Short press
▶ Short press Menu down
Menu up Parameter value down (step-wise)
Parameter value up (step-wise)
▶ Long press
▶ Long press Menu down
Menu up Parameter value down (fast)
Parameter value up (fast)

Display mode
▶ Short press
Display of the unit
11430486.07 04/2015 EN/DE/FR/ES

Programming mode
▶ Short press
Select menu item
Confirmation of the input

WIKA operating instructions pressure switch, model PSD-3x 23

 6. Commissioning, operation
6.5 Parameters

Parameter Description
EN SP1/SP2 Hysteresis function: Switch point switching output (1 or 2)
FH1/FH2 Window function: Window high switching output (1 or 2)
RP1/RP2 Hysteresis function: Reset point switching output (1 or 2)
FL1/FL2 Window function: Window low switch output (1 or 2)
EF Extended programming functions
RES Return the set parameter to the factory settings
DS1/DS2 Switch delay time, which must occur without interruption before any electrical signal change occurs (SP1 or SP2)
DR1/DR2 Switch delay time, which must occur without interruption before any electrical signal change occurs (RP1 or RP2)
OU1 Switching function switching output (1 or 2)
OU2 HNO = hysteresis function, normally open
HNC = hysteresis function, normally closed
FNO = window function, normally open
FNC = window function, normally closed
UNIT Unit switching
0SET Offset adjustment (3 % of span)
DISM Display value in display mode
ACT = actual pressure value; LOW, HIGH = minimum, maximum pressure value OFF = display off;
SP1/FH1 = function switch point 1, RP1/FL1 = function reset point 1,
SP2/FH2 = function switch point 2, RP2/FL2 = function reset point 2
DISU Display update 1, 2, 5, 10 updates/second
DISR Rotate display indicator by 180°
RHL Clear the Min- and Max-value memories

11430486.07 04/2015 EN/DE/FR/ES

PAS Password input, 0000 = no password
Password input digit by digit
TAG Input of a 16-figure alphanumeric measuring point number

24 WIKA operating instructions pressure switch, model PSD-3x

 6. Commissioning, operation
Menu (programming and factory setting)
Display mode
Long press on menu key
Programming mode Factory setting:
EN
SP1 / FH1 Value (Min: MBA +0.5 % Max: MBE) Instrument nominal pressure

RP1 / FL1 Value (Min: MBA Max: SP1 -0.5 %) Instrument nominal pressure -10 %

SP2 / FH2 Value (Min: MBA +0.5 % Max: MBE) Instrument nominal pressure

RP2 / FL2 Value (Min: MBA Max: SP2 -0.5 %) Instrument nominal pressure -10 %

EF RES Yes / No Reset to factory setting

DS1 Value 0 ... 50 s 0s

DR1 Value 0 ... 50 s 0s

DS2 Value 0 ... 50 s 0s

DR2 Value 0 ... 50 s 0s

OU1 PARA HNO, HNC, FNO, FNC HNO

OU2 PARA HNO, HNC, FNO, FNC HNO

UNIT Unit BAR, MPA, KPA, PSI, KG/cm2 Order-related

0SET Yes / No Zero point adjustment 3% of span

ACT, HIGH, LOW, OFF, SP1/FH1, RP1/
DISM PARA ACT
FL1, SP2/FH2, RP2/FL2
DISU Value 1/2/5/10 update/second 5
11430486.07 04/2015 EN/DE/FR/ES

DISR Yes / No Rotate display by 180°

RHL Yes / No Reset HIGH, LOW

PAS Value Password without

TAG Value Measuring point number without

END END
Legend:
MBA = Start of measuring range
Display mode MBE = End of measuring range

WIKA operating instructions pressure switch, model PSD-3x 25

 6. Commissioning, operation
6.6 Switching functions

Hysteresis function
EN If the system pressure fluctuates around the set point, the hysteresis
keeps the switching status of the outputs stable. With increasing system
pressure, the output switches when reaching the switch point (SP).

■■ Contact normally open (HNO): active

■■ Contact normally closed (HNC): inactive

With system pressure falling again, the output will not switch back
before the reset point (RP) is reached.
Fig.: Hysteresis function
■■ Contact normally open (HNO): inactive
■■ Contact normally closed (HNC): active

Window function
The window function allows for the control of a defined range.
When the system pressure is between window High (FH) and window
Low (FL), the output switches on.

■■ Contact normally open (FNO): active

■■ Contact normally closed (FNC): inactive

11430486.07 04/2015 EN/DE/FR/ES

When the system pressure is outside window High (FH) and window
Low (FL), the output does not switch on.

■■ Contact normally open (FNO): inactive

■■ Contact normally closed (FNC): active
Fig.: Window function

26 WIKA operating instructions pressure switch, model PSD-3x

 6. Commissioning, operation
Delay times (0 ... 50 s)
This makes it possible to filter out unwanted pressure peaks of a short
duration or a high frequency (damping).
The pressure must be present for at least a certain pre-set time for the EN
output to switch on. The output does not immediately change its status
when it reaches the switching event (SP), but rather only after the
pre-set delay time (DS).

If the switching event is no longer present after the delay time, the
switch output does not change.
The output only switches back when the system pressure has fallen
down to the reset point (PR) and stays at or below the reset point (RP) Fig.: Delay times
for at least the pre-set delay time (DR).

If the switching event is no longer present after the delay time, the
switch output does not change.

6.7 Description of the IO-Link functionality (optional)

IO-Link is a point-to-point connection for the communication of the PSD-3x with an IO-Link master.

IO-Link specification: Version 1.1

A detailed description of the IO-Link functionality and the device description file (IODD) can be found
online on the product details page of the pressure switch at www.wika.com.
11430486.07 04/2015 EN/DE/FR/ES

WIKA operating instructions pressure switch, model PSD-3x 27

 7. Maintenance and cleaning
7. Maintenance and cleaning
7.1 Maintenance
EN This instrument is maitenance-free.
Repairs must only be carried out by the manufacturer.

7.2 Cleaning

CAUTION!
■■ Before cleaning, correctly disconnect the instrument from the pressure supply, switch it
off and disconnect it from the mains.
■■ Clean the instrument with a moist cloth.
■■ Electrical connections must not come into contact with moisture.
■■ Wash or clean the dismounted instrument before returning it in order to protect personnel
and the environment from exposure to residual media.
■■ Residual media in dismounted instruments can result in a risk to persons, the
environment and equipment.
■■ Take sufficient precautionary measures.
■■ Do not use any pointed or hard objects for cleaning, as they may damage the diaphragm
of the process connection.

For information on returning the instrument see chapter 9.2 "Return".

11430486.07 04/2015 EN/DE/FR/ES

28 WIKA operating instructions pressure switch, model PSD-3x
 8. Faults
8. Faults

In the event of any faults, first check whether the pressure switch is mounted correctly, EN
mechanically and electrically.

Error display
Via the instrument's display internal errors of the instrument are output.
The following table shows the error codes and their meaning.

Error Description
ATT1 On changing the switch point, the system automatically reduces the reset point.
ATT2 Zero-point adjustment error, current pressure is outside the limits
ATT3 Password entered for menu access is incorrect
ATT4 TAG cannot be shown in the display (e.g. special characters)
ERR Internal error
OL Overpressure, measuring range exceeded > approx. 5% (display blinks)
UL Underpressure, below measuring range < approx. 5 % (display blinks)

Acknowledgement of an error display by pressing the „Enter“ key.

11430486.07 04/2015 EN/DE/FR/ES

WIKA operating instructions pressure switch, model PSD-3x 29

 8. Faults
Problem Possible cause Measure
No output signal Cable break Check the continuity
No output signal No/wrong power supply Rectify the power supply
EN No/wrong output signal Wiring error Observe the pin assignment
Constant output signal upon change Mechanical overload caused by over- Replace instrument; if it fails repeatedly,
in pressure pressure contact the manufacturer
Deviating zero point signal Overpressure limit exceeded Observe the permissible overpressure limit
Signal span too small Mechanical overload caused by over- Replace instrument; if it fails repeatedly,
pressure contact the manufacturer
Signal span too small Power supply too high/low Rectify the power supply
Signal span drops Humidity has entered Assemble the cable correctly
Signal span drops/too small Diaphragm damaged, e.g. due to Contact manufacturer and replace
impacts, abrasive/aggressive medium; instrument
corrosion at diaphragm/process
connection
If complaint is unjustified, we will charge you the complaint processing fees.

CAUTION!
If deficiencies cannot be eliminated by means of the measures listed above, shut down the
instrument immediately, and ensure that pressure and/or signal are no longer present, and
secure the instrument from being put back into operation inadvertently. In this case, contact
the manufacturer. If a return is needed, follow the instructions given in chapter 9.2 "Return".

11430486.07 04/2015 EN/DE/FR/ES

30 WIKA operating instructions pressure switch, model PSD-3x
 9. Dismounting, return and disposal
9. Dismounting, return and disposal
WARNING!
Residual media in dismounted pressure switches can result in a risk to persons, the EN
environment and equipment.
Take sufficient precautionary measures.

9.1 Dismounting
Only disconnect the pressure switch once the system has been depressurised!

9.2 Returns

WARNING!
Absolutely observe the following when shipping the instrument:
All instruments delivered to WIKA must be free from any kind of hazardous substances
(acids, leachate, solutions, etc.).

When returning the instrument, use the original packaging or a suitable transport package.

Enclose the completed return form with the instrument.

The return form can be found under the heading 'Service' at www.wika.com
11430486.07 04/2015 EN/DE/FR/ES

9.3 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an environmentally compatible way and
in accordance with the country-specific waste disposal regulations.

WIKA operating instructions pressure switch, model PSD-3x 31

 Appendix 1: EC Declaration of Conformity for model PSD-3x

EN

11430486.07 04/2015 EN/DE/FR/ES

32 WIKA operating instructions pressure switch, model PSD-3x
 Mechanical
pressure measurement

Bourdon tube pressure gauge

Model 213.53, liquid filling, stainless steel case
WIKA data sheet PM 02.12

for further approvals

see page 2

Applications
■■ For measuring points with high dynamic pressure loads or
vibrations
■■ For gaseous and liquid media that are not highly viscous
or crystallising and will not attack copper alloy parts
■■ Hydraulics
■■ Compressors, shipbuilding

Special features
■■ Vibration and shock resistant
■■ Especially sturdy design
■■ NS 63 and 100 with German Lloyd and Gosstandart
approval
■■ Scale ranges up to 0 ... 1,000 bar Bourdon tube pressure gauge, model 213.53.100,
lower mount

Description Pressure limitation

NS 50, 63: Steady: 3/4 x full scale value
Design Fluctuating: 2/3 x full scale value
EN 837-1 Short time: Full scale value
NS 100: Steady: Full scale value
Nominal size in mm Fluctuating: 0.9 x full scale value
50, 63, 100 Short time: 1.3 x full scale value

Accuracy class Permissible temperature

NS 50, 63: 1.6 Ambient: -20 ... +60 °C
NS 100: 1.0 Medium: +60 °C maximum

Scale ranges Temperature effect

NS 50: 0 ... 1 to 0 ... 400 bar When the temperature of the measuring system deviates
NS 63, 100: 0 ... 0.6 to 0 ... 1,000 bar from the reference temperature (+20 °C):
or all other equivalent vacuum or combined pressure and Max. ±0.4 %/10 K of the span
vacuum ranges
Ingress protection
IP 65 per EN 60529 / lEC 60529

WIKA data sheet PM 02.12 ∙ 03/2015 Page 1 of 3

Data sheets showing similar products:

Standard version with liquid filling; model 113.53; see data sheet PM 01.08
Standard version Options

Process connection ■■ Other process connection

Copper alloy, ■■ Sealings (model 910.17, see data sheet AC 09.08)
lower mount (LM) or back mount (BM), ■■ Measuring system and movement from stainless steel
NS 50, 63: G ¼ B (male), 14 mm flats (model 233.53)
NS 100: G ½ B (male), 22 mm flats ■■ NS 100: Zero adjustment (in front)
■■ Increased medium temperature with special soft solder
Pressure element - NS 50, 63: 100 °C
NS 50: - NS 100: 150 °C
Copper alloy, C-type or helical type ■■ Ambient temperature resistant -40 ... +60 °C with silicone
oil filling
NS 63: ■■ NS 50: Higher scale ranges up to 0 ... 1,000 bar
≤ 400 bar: Copper alloy, C-type or helical type ■■ Panel mounting flange, stainless steel, for back connection
> 400 bar: Stainless steel 316L, helical type ■■ Surface mounting flange, stainless steel (not NS 50)
■■ Mounting clamp (for back connection)
NS 100:
< 100 bar: Copper alloy, C-type
≥ 100 bar: Stainless steel 316L, helical type

Movement
Copper alloy CE conformity
Dial
Pressure equipment directive
NS 50, 63: Plastic ABS, white, with pointer stop pin
97/23/EC, PS > 200 bar, module A, pressure accessory
NS 100: Aluminium, white, black lettering

Pointer
NS 50, 63: Plastic, black
Approvals
NS 100: Aluminium, black
■■ GL, ships, shipbuilding (e.g. offshore), Germany
■■ EAC, import certificate, customs union Russia/Belarus/
Window
Plastic, crystal-clear Kazakhstan
■■ GOST, metrology/measurement technology, Russia
■■ KBA, automotive, European Community
Case
■■ CRN, safety (e.g. electr. safety, overpressure, ...), Canada
Natural finish stainless steel, with blow-out device with
NS 50: in case back, 12 o‘clock
NS 63, 100: at case circumference, 12 o‘clock Certificates 1)
O-ring seal between case and connection.
Scale ranges ≤ 0 ... 16 bar with compensating valve to vent ■■ 2.2 test report per EN 10204 (e.g. state-of-the-art
case. manufacturing, material proof, indication accuracy)
■■ 3.1 inspection certificate per EN 10204 (e.g. indication
Bezel ring accuracy)
Crimp ring, glossy finish stainless steel, triangular bezel

Filling liquid 1) Option

Glycerine
Approvals and certificates, see website

Page 2 of 3 WIKA data sheet PM 02.12 ∙ 03/2015

 Dimensions in mm
Standard version
Lower mount (LM)

1224557.01
NS 50, 63, centre back mount (CBM) NS 100, lower back mount (LBM)

31059155.01

11081163.01
NS Dimensions in mm Weight in kg
a b ±0.5 b2 ±0.5 D1 D2 e f G h ±1 SW
50 12 30 55 55 50 5.5 - G¼B 48 14 0.15
63 13 32 56 68 62 6.5 - G¼B 54 14 0.21
100 15.5 48 81.5 107 100 8 30 G½B 87 22 0.80
Process connection per EN 837-1 / 7.3

Ordering information
Model / Nominal size / Scale range / Connection size / Connection location / Options

© 2008 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.

WIKA data sheet PM 02.12 ∙ 03/2015 Page 3 of 3

03/2015 EN

WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. +49 9372 132-0
Fax +49 9372 132-406
[email protected]
www.wika.de
 Operating 1. Safety gauge, it must be protected against being blocked
instructions EN WARNING!
by debris and dirt. With safety pressure gauges
(see k) there must be a free space of > 15 mm
Before installation, commissioning and
behind the blow-out back.
operation, ensure that the appropriate
After installation, open the vent valve (if available)
Pressure gauges pressure gauge has been selected in
or set from CLOSE to OPEN. With
terms of measuring range, design and
models 4 and 7, do not open the
suitable wetted material (corrosion) for the specific
flange mounting screws. The version
measuring conditions. In order to guarantee the
of the vent valve depends on the
measurement accuracy and long-term stability
Examples: model and can deviate from the above illustration!
specified, the corresponding load limits must be
observed. Requirements for the installation point
Only qualified persons authorised by the plant If the line to the measuring instrument is not
manager are permitted to install, maintain and adequately stable, a measuring instrument holder
service the pressure gauges. should be used for fastening (and possibly via a
Model 732.14, flexible capillary). If vibrations cannot be avoided
For hazardous media such as oxygen, acetylene,
overpressure safety by means of suitable installation, instruments
flammable or toxic gases or liquids, and refrige-
up to 400 bar with liquid filling should be used. The instruments
ration plants, compressors, etc., in addition to
Model 432.56, should be protected against coarse dirt and wide
all standard regulations, the appropriate existing
overpressure safety fluctuations in ambient temperature.
codes or regulations must also be followed.
up to 100 bar Note for model 732.14, for front bezel mounting:
From pressure gauges which do not correspond The front bezel serves as centring and as the
Model 213.40 to a safety version per EN 837 highly pressurised aperture in the mounting panel. Securing and thus
media might leak out through the possibly bursting the weight-bearing must be made via the pressure
window in case of a component failure. For connection piping.
gaseous media and working pressures > 25 bar a
pressure gauge with safety version S3 is recom- 3. Permissible ambient and operating
mended per EN 837-2. temperatures
After an external fire, pressure media can leak out, When mounting the pressure gauge it must be
Notes per pressure equipment directive 97/23/EC particularly at soft solder joints. All instruments ensured that, taking into consideration the influen-
„„ The pressure gauges are “pressure must be checked and, if necessary, replaced ce of convection and heat radiation, no deviation
accessories” per article 1, para. 2.1.4 before recommissioning the plant. above or below the permissible temperature limits
„„ The volume of the pressure-bearing housings of can occur. Observe the influence of temperature
Non-observance of the respective regulations on the indication accuracy!
WIKA pressure gauges is < 0.1 L can cause serious injuries and/or damage to the
„„ The pressure gauges carry CE marking for fluid equipment. 4. Storage
group 1G per annex 2, diagram 1 when their
permissible working pressure is > 200 bar 2. Mechanical connection To protect the pressure gauges from mechanical
damage keep them in the original packaging until
Instruments that do not carry the mark are In accordance with the general technical regula- installation.
manufactured per article 3, paragraph 3 “Sound tions for pressure gauges (e.g. EN 837-2). When Protect the measuring instruments from humidity
engineering practice”. screwing the instruments in, the force required to and dust.
Applicable standards (depending on model) do this must not be applied through the case, but Storage temperature range: -40 ... +70 °C
only through the spanner flats provided for this Storage temperature range model
EN 837-1 Bourdon tube pressure gauges, dimensions, purpose, and using a suitable tool.
metrology, requirements and testing PG23LT: -70 ... +70 °C
For parallel threads, use flat gaskets, lens-type
EN 837-2 Selection and installation recommendations sealing rings or WIKA profile sealings at the 5. Maintenance and repairs
for pressure gauges
EN 837-3 Diaphragm and capsule pressure gauges, The pressure gauges are maintenance-free.
dimensions, metrology, requirements and Regular checks should be carried out to ensure
testing Installation with the measurement accuracy. Checks or recalibra-
open-ended tions must only be carried out by qualified skilled
Specifications: See data sheet at www.wika.de spanner personnel with the appropriate equipment. When
Subject to technical modifications. dismounting, close the vent valve (if available).
Sealing of the pressure gauge connections
© WIKA Alexander Wiegand SE & Co. KG 2009 WARNING! Residual media in
Sealing in dismounted pressure gauges can
Spanner flats the thread result in a risk to persons, the environ-
 ment and equipment. Take sufficient
Sealing face  precautionary measures.
sealing face . With tapered threads (e.g. NPT
WIKA Alexander Wiegand SE & Co. KG threads), sealing is made in the threads  using
Alexander-Wiegand-Straße 30 additional sealing materials, e.g. PTFE tape
2408976.05 05/2016

63911 Klingenberg/Germany (EN 837-2).

Tel. +49 9372 132-0 The torque depends on the sealing used. In order
Fax +49 9372 132-406 to orientate the measuring instrument so that it
[email protected] can be read as well as possible, a connection with
www.wika.de clamp socket or union nut should be used.
When a blow-out device is fitted to a pressure