LPBP HPSU Document PDF

Documentation
for
Hydraulic Power Supply Unit
with Hydraulic Control Units for two pieces LP Bypass
Stop Valves and two pieces LP Bypass Control Valves
BOMAFA-Com.-No.: 1400655/2015
asfa-Com.-No.: H-10595-HA
Order No.: B5V6275
Bharat Heavy Electrical Limited (India)

Project: Bhadradri 3&4 (4 x 270 MW)
Date: 2017-01-30
asfa-Antriebssysteme
Ferdinand Appelberg GmbH
 Hohensteinstraße 52
44866 Bochum (Germany)
 +49 (0) 2327 / 992-200 E -  info@asfa-antriebe.de
 +49 (0) 2327 / 31443 Internet: http://www.asfa-antriebe.de
Bharat Heavy Electrical Limited (Bhadradri 3&4 (4 x 270 MW); India)
Hydraulic unit for two pieces LP Bypass Stop Valves and two pieces LP Bypass Control Valves
asfa-Comm. No.: H-10595-HA
Date: 2017-01-30
DOCUMENTATION
1. Contents
1.1 Functional description
1.2 Instructions for commissioning and maintenance
1.3 P+I Diagrams
Drawing No. 1L 12728/A (HPSU)
Drawing No. 2L 12729/A (Actuator for LP Bypass Stop Valve)
Drawing No. 2L 12730/A (Actuator for LP Bypass Control Valve)
Client parts lists
1.4 Hydraulic Power Supply Unit (HPSU) 450 ltr.
Drawing No. 0L 12318/A
1.5 Hydraulic Control Units with actuator
Hydraulic Control Unit for LP Bypass Stop Valve
Type CER 250 C 125/56x125 DV
Drawing No. 1L 12050/D
Hydraulic Control Unit for LP Bypass Control Valve
Type CD 250 C 80/36x155 DBUW
Drawing No. 1L 12051/E
Client parts lists
1.6 Electrical documentation (wiring drawing)
Wiring drawing (Drawing No. PP01201 /1400655)
1.7 Acceptance test documents
1.8 Data sheets for components
1.1
Functional description
Hydraulic Power Supply Unit (HPSU) and Hydraulic Actuators - Functional Description
Customer: Bharat Heavy Electrical Limited (India)
Hydraulic unit for two pieces LP Bypass Stop Valves and two pieces LP Bypass Control Valves
P+I-Diagram Drawing-No.: 1L 12728/A (HPSU)
2L 12729/A (Actuator for LP Bypass Stop Valve)
2L 12730/A (Actuator for LP Bypass Control Valve)
Date: 2017-01-30
Setting ranges of the components

Item KKS Designation of the components Setting range
50 MAX05 CL001 Oil level transmitter 4 to 20 mA 0 to 100% level
55 MAX05 CT001 Temperature transmitter 4 to 20 mA (2 wire, 24 V DC) -25 to 100°C
56 MAX05 CT002 Temperature transmitter 4 to 20 mA (2 wire, 24 V DC) -25 to 100°C
120 MAX05 CP011 Difference pressure switch (HP filter) Δp = 5 bar -10%
121 MAX05 CP012 Difference pressure switch (HP filter) Δp = 5 bar -10%
170 MAX05 AA091 Pressure limiting valve 180 bar
171 MAX05 AA092 Pressure limiting valve 180 bar
179 MAX05 CP027 Pressure switch (filter in oil regeneration unit) ≤ 1 bar
180 MAX05 CP001 Pressure transmitter 4 to 20 mA Pump 1 (2 wire, 24 V DC) 0 to 600 bar
181 MAX05 CP002 Pressure transmitter 4 to 20 mA Pump 2 (2 wire, 24 V DC) 0 to 600 bar
182 MAX05 CP003 Pressure transmitter 4 to 20 mA HPSU (2 wire, 24 V DC) 0 to 600 bar
183 MAX05 CP020 Pressure switch pdeep oil cooler 1 ≤ 1.0 bar
184 MAX05 CP021 Pressure switch pdeep oil cooler 2 ≤ 1.0 bar
185 MAX05 CP026 Pressure switch pdeep oil regeneration unit ≤ 0.5 bar
810 MAX05 BB011 Nitrogen precharging pressure for the accumulator 103.5 bar
811 MAX05 BB013 Nitrogen precharging pressure for the accumulator 103.5 bar
Page 1 of 6 Functional description HPSU

Functional description
After the electric motor (item 100 or item 101) has been switched on and also the 2/2 way so-
lenoid valves (item 320 and item 321) are switched on, the corresponding pump (item 70/71;
Qpump = 26.0 l/min.) delivers the hydraulic fluid (oil) via non return valve (item 110 or item 111)
to the connection „P" of the pressure limiting valve (item 170 or item 171) and via high-pressure
filter (item 120 or item 121) with electrical soiling indication, as well as via non return valve
(item 112 or item 113) to the pressure transmitter (item 180, item 181 and item 182) and to
storage connection „PSP“ of the 2 pieces hydro-bladder accumulators (item 810 and item 811).
Further, the pressurized oil flows via the shut-off cocks (item 190 and item 191) to the two con-
nection ports ("P1" and "P2") at the Hydraulic Power Supply Unit (HPSU) and from there to
connections "P" of the Hydraulic Control Units at the actuators of the LP Bypass Stop Valves
and the LP Bypass Control Valves.
After the medium has flown via the opened shut-off cocks (item 830 and item 831) into the ac-
cumulator vessel, and when the gas volumes (nitrogen) inside the bladder has been com-
pressed to working pressure, the HPSU is ready for operation.
Oil-pump control
The operation of the oil pump motors should occur in the Distributed Control System (DCS)
and should be implemented as follows:
One oil pump motor must be preselected as a main engine. The second oil pump motor must
be available as stand by. With loss of the preselected oil pump motor (for example the protec-
tive motor switch is triggered) the stand by oil pump motor must take over the supply of the
Hydraulic Power Supply Unit (HPSU). The preselection of the oil pump motor should occur au-
tomatically.
Both oil-pump motors are controlled with the three pressure transmitters (item 180 to item 182)
and in normal case the preselected oil-pump motor is running continuously. If the oil pressure
at the pressure transmitters falls below 160 bar, the 2/2 way solenoid valves (item 320 and item
321) must be switched on. The 2/2 way solenoid valve (item 320) is responsible for the oil pump
(item 70) and the 2/2 way solenoid valve (item 321) is responsible for the oil pump (item 71).
If the oil pressure at the pressure transmitters exceeds 165 bar, the 2/2 way solenoid valves
(item 320 and item 321) must be switched off. Now the preselected pump is running continu-
ously with a pressure-free circulation of the oil back into the oil tank.
The oil pump motors is not allowed to start or has to be stopped, when the oil level has fallen
under Lmin.min (item 50a / 51a / 52a).
Fault messages
The oil-level inside the oil tank (item 10) is monitored by three level transmitters (level indica-
tor; item 50, item 51 and item 52) which should have two signals:
- Lmin (item 50b, item 51b and item 52b)
- Lmin.min (item 50a, item 51a and item 52a)

Lmin should be fault messages that does not affect the control of the oil-pumps, whereas the
messages Lmin.min should switch them off.
The differential pressure switch at the pressure filters (item 120 and item 121) should be han-
dled just as warning. This signal should not affect the control of the Hydraulic Power Supply
Unit (HPSU); it should be understood as a warning signal for maintenance.
The filter element of the clogged pressure filter has to be replaced within 24 hours after the
warning signal is given. The replacement of the filter element is possible during operation of
the HPSU. The related pump motor has to be switched OFF (refer to maintenance instructions).
Manual operated shut-off valves at the pressure filters

For maintenance (change of filter elements during operation), repairs and in case of failed
components, manual operated shut-off valves are installed to stop or change over the oil flow
as shown in the hydraulic circuit diagram.
Pressure filter (item 120) can be isolated from oil flow by closing the shut-off valves (item 194
and item 195) for example.
Pressure filter (item 121) can be supplied from the oil pump (item 70) by opening the shut-off
valve (item 198) and closing the shut-off valve (item 194) for example.
Controlling of the oil-air-coolers and the regeneration unit

The controlling of the two oil-air-coolers (item 65 and item 66) and the regeneration unit (item
67) should occur in the Distributed Control System (DCS) and should be implemented as fol-
lows:
One of the two motor-pump units of the oil-air-cooler (item 65 and item 66) should run continu-
ously; the second must be available as stand by. The oil contained in the oil tank (item 10) has
to be continuous in circulation and is filtered without being cooled. Also the oil is in circulation
through the regeneration unit and therefore the fire-resistant hydraulic oil is continuously re-
generated.
If the oil temperature increases to 62°C, the motors of the fan of the corresponding oil air cool-
ers must be started from the Distributed Control System (DCS) and so the warmed up oil is
cooled through the oil air cooler with the fan.
If the oil temperature is fallen under 60°C, the motors of the fan of the oil air coolers has to be
switched off from the Distributed Control System (DCS) and so the oil is only filtered again.
In case that the oil temperature rise up to 65°C, there should be an alarm signal to the DCS or
both motor pumps units and both air cooler fans should be switched on by the DCS to cool
down the hydraulic fluid.
In case that the oil temperature rise up to 75°C, the main oil pumps (item 100 and item 101)
should be switched off by the DCS, while both motor pumps units (item 102 and item 103) and
both air cooler fans (item 104 and item 105) should be continuously running to cool down the
hydraulic fluid.

For monitoring the oil flow of the pump (item 102) in the oil cooling circuit (item 65), pressure
switch (item 183) gives signal 1 when the oil flow is sufficient.
In case that the pump (item 102) is selected as duty and switched on by the DCS, but the
pressure switch (item 183) gives signal 0, an automatic change over to cooling circuit (item 66)
with the pump (item 103) is recommended. The failure at cooling circuit (item 65) has to be
checked and repaired.
The same control function is recommended for the pump (item 103) if the corresponding pres-
sure switch (item 184) gives signal 0.
For monitoring the oil flow to the oil regeneration unit (item 67), pressure switch (item 185)
gives signal 1 when the oil flow is sufficient.
In case that the pump (item 102) is selected as duty and switched on by the DCS, but the
pressure switch (item 185) gives signal 0, an automatic change over to the pump (item 103) is
recommended. The failure at the pump (item 102) has to be checked and repaired.
Filter monitoring of the oil-air-cooling circuits and of the regeneration unit

The differential pressure switches (MAX05 CP013 and MAX05 CP014) at the return line filters
(MAX05 AT013 and MAX05 AT014) in the oil-air-cooling circuits (item 65 and item 66) should
be handled just at warning. This signal should not affect the control of the Hydraulic Power
Supply Unit (HPSU); it should be understood as a warning signal for maintenance.
The filter element of the clogged return line filter has to be replaced within 24 hours after the
the HPSU. The related pump motor has to be switched OFF (refer to maintenance instruc-
tions).
The pressure switch (item 179; MAX05 CP027) before the filter in the line of the regeneration
unit (item 67) should be handled just at warning. This signal should not affect the control of the
Hydraulic Power Supply Unit (HPSU); it should be understood as a warning signal for mainte-
nance.
The filter element of the clogged return line filter has to be replaced within 24 hours after the
the HPSU. The related shut-off valves (MAX05 AA260 and MAX05 AA261) have to be closed
to stop the oil flow through the return line filter (MAX05 AT016).
The oil flow coming from the pump (MAX05 AP011 / AP012) will be released back to the tank
by opening the check valve (MAX05 AA042) at 3 bar.
Manual operated shut-off valves at the oil-air-cooling circuits and at the regeneration unit
For maintenance (change of filter elements during operation), repairs and in case of failed
components, manual operated shut-off valves (ball valves) are installed to stop or change over
the oil flow as shown in the hydraulic circuit diagram.
Oil cooling circuit (item 65) can be supplied from the pump (item 103) by opening ball valve
(MAX05 AA250) and closing ball valve (MAX05 AA252) for example.

Accumulator unit
The boost pressure of the hydro-bladder accumulators (item 810 and item 811; accumulators
for the working pressure) base upon the non return valves (item 112 and item 113).
The nitrogen pre charging pressure for the accumulators is p0 = 103.5 bar. Based on an accu-
mulator rated volume of 32 litres for the hydro-bladder accumulator (item 810 and item 811),
the extraction volume of this accumulator at max. charge is approx. 6.2 litres.
If repairs have to be done at the hydraulic system it is absolutely necessary to switch OFF all
motors and - very important - to discharge the hydro-bladder accumulators on the oil-delivery
side via shut-off cocks (item 850 and item 851) before opening a pipeline or replacing a valve.
The pressure indicator of the pressure gauges (item 860 and item 861) must indicate 0 bar.
Operational control of valves

The pressurized oil flows from the Hydraulic Power Supply Unit (HPSU) via the piping to the
Hydraulic Control Units, which are mounted directly at the hydraulic actuators.
Further adjustments on the valves / hydraulic cylinders could be effected as follows:

- Opening of the LP Bypass Stop Valves (2 pieces; see P+I-Diagram 2L 12729/A):
In case of an opening event by an external trip action from the Distributed Control System
(DCS), the 3/2 way solenoid valve (item 350) which is connected according to the normally-
closed principle, is switched on.
Adjustment of opening time of the LP Bypass Stop Valve of about 2 seconds at flow control
valve (item 360).
- Closing of the LP Bypass Stop Valves (2 pieces; see P+I-Diagram 2L 12729/A):
In case of a closing event by an external trip action from the Distributed Control System
(DCS) or a loss of electric power, the 3/2 way solenoid valve (item 350) which is connected
according to the normally-closed principle, is switched off and so the LP Bypass Stop Valve
closes in 2 seconds.
- Quick-Closing of the LP Bypass Stop Valves (2 pieces; see P+I-Diagram 2L 12729/A):
In case of a quick-closing event by an external trip action from the Distributed Control Sys-
tem (DCS) or a loss of electric power, the two 3/2 way solenoid valves (TSV; item 351 and
item 352) which are connected according to the normally-closed principle, are switched off
and so the LP Bypass Stop Valve closes quickly within in 1 second.
- Controlling of the LP Bypass Control Valves (2 pieces; see P+I-Diagram 2L 12730/A):
The controlling of the LP Bypass Control Valves must be done in the Distributed Control
System (DCS) there an arrangement must occur between the set point and the actual val-
ue. This can produce a control deviation. In response to this deviation, a positive or nega-
tive current signal (max. ± 30 mA) must be admitted to the servo valve (item 310). This
causes re-adjustment of the LP Bypass Control Valves until the deviation becomes zero.
The control time is about 2 seconds.
Remark: If a maximum current signal of ± 30 mA comes from the DCS, the electrical con-
nection of the two coils of the servo valve must be in series.

The actual value is fed back as a current signal of 4 to 20 mA (corresponds 0 to 100 %
stroke) by means of the ultrasonic position measuring system (item 581) integrated in the
hydraulic cylinder.
4 mA = valve closed (0%)
20 mA = valve open (100%)
Permanent set point/actual-value comparison now causes the LP Bypass Control Valves to
exactly stay in their predetermined position.
- Locking of the LP Bypass Control Valves (2 pieces; see P+I-Diagram 2L 12730/A):
In case of an locking event by an external signal from the Distributed Control System
(DCS), the 3/2 way solenoid valve (item 353) which is connected according to the normally-
opened principle, is switched on and so the hydraulic actuator as well as the LP Bypass
Control Valve is locked in the last position.
General information
The current pressure values can be read from the pressure gauges (item 186 to item 189, item
860 and item 861) and from the "M" measuring connection ports.
Reference regarding maintenance and commissioning is made to the attached operation &
maintenance instructions as well as the oil specification.

1.2
Instructions of commissioning
and maintenance
Installation Instruction
for
BOMAFA-Com.-No.: 1400655/2015
Order No.: B5V6275

Date: 2017-01-30
GENERAL INSTRUCTIONS FOR INSTALLATION OF THE HPSU
READ THIS INSTRUCTION COMPLETELY BEFORE INSTALLATION
The position Nos. mentioned in the following description are shown in the P+I hydraulic dia-
gram 1L 12728/A and on the dimensional drawing 0L 12318/A.
The HPSU and its accessories (cylinders, hydraulic fluid, installation material, special tools)
shall be stored in the transport container or in a building on site.
Just before beginning of the installation the HPSU shall be taken out of the transport contain-
er or the storage building.
The HPSU with enclosure is designed for indoor installation under the specified side conditions.
But for resist these conditions over a long time, the HPSU must be completely installed, filled
with hydraulic fluid and supplied with electric power for the fluid regeneration unit.
For transportation and lifting the HPSU is skid mounted on a frame and equipped with 4 lifting
eyes on top of the enclosure. The mass of the HPSU (including the oil filling) is approximately
2800 kg.
ATTENTION:
All 4 with lifting eyes have to be hooked up together for lifting up the HPSU!
Handle with care during transportation and installation.
The lifting eyes are also used as fixing points of the roof over the HPSU.
After transportation and installation are finished, the lifting eyes shall be replaced by screws.
The position of the HPSU in relation to the Bypass Valves is important for the installation of
the external pipes to the hydraulic cylinders and for the installation of the electric cables.
Put the base frame of the HPSU directly on a plain concrete basement or steel construction
and fix it with 4 anchor bolts.
An oil tub is also part of the HPSU and it is already assembled on the skid inside the enclosure.
All doors and side walls of the HPSU enclosure as well as the doors of the electric terminal
cabinet shall remain closed. Only for access work inside the doors might be opened, but
closed tight again as soon as possible.
After transportation and installation are finished, check the painting of the complete enclosure
and do all necessary repair as soon as possible.
The external hydraulic piping between the power pack and the hydraulic cylinders shall be
installed on site according to applicable Installation Instruction for Hydraulic Pipework.
At least the external piping has to be pressure tested with the max. operating pressure and
cleaned by intensive flushing after installation according to applicable Flushing Instruction!
Page 1 / 4 Installation HPSU 2017-01-30

Filling of the oil tank with hydraulic fluid
After installation of the HPSU, the cylinders and the external piping, just before flushing of the
external piping shall be done, fill in Hydraulic Fluid, for example Type FYRQUEL EHC-N.
Never use any other hydraulic fluid! Otherwise the complete HPSU might be damaged.
Use a filling pump device and connect the flexible hose to the filling connection at the return oil
filter MAX05AT013. Fill up hydraulic fluid to the top of the oil level sight glass (approx. 450 l).
Watch the optical clogging indicator on top of the filling filter. If the indicator changes from
green to yellow light, stop the motor filling pump and change the filter element of the filling filter.
The old filter element can not be cleaned and has to be disposed to hazardous waste.
Use original packed and clean spare filter elements only.
The filter fineness must be 10 µm.
Check if all seals are installed correctly.

Check the tightness of the covers on the inspection openings at the oil tank.
Hydraulic Accumulators, Nitrogen Pressure
Fill up and check the nitrogen pressure at all the accumulators with the special filling
and test device (special tool, part of our delivery).
The operation instructions are included in this instruction and also in the service case of the
nitrogen pressure filling and test device.
The required nitrogen filling pressure is mentioned in the P+I hydraulic diagram and on the
warning labels at the accumulators at the HPSU.
Use nitrogen bottles with minimum 99.5% nitrogen only! Never use any other gas for
filling!
For access to the accumulators inside the encapsulation of the HPSU, take off the side walls
just before beginning of this work and close the side walls tight again after finishing the work.
Never switch on the main pumps of the HPSU without sufficient nitrogen pressure.
Otherwise the bladder inside the accumulator will be damaged.
Also the emergency function of the dampers is only possible with sufficient nitrogen pressure
inside the bladder of the accumulators.

Pipework between Hydraulic Power Supply Unit (HPSU) and Hydraulic Control Units
In the hydraulic diagrams of the Hydraulic Power Supply Unit (HPSU; 1L 12728/A), of the LP
Bypass Stop Valves (2L 12729/A) and of the LP Bypass Control Valves (2L 12730/A) the
connections for pressure and return oil and the tubes used together with its external diameter
and wall thickness are given.
For the connection between Hydraulic Power Supply Unit (HPSU) / pipework and pipework /
Hydraulic Control Units at the actuators flexible high pressure hoses must be used. These
hoses must be mounted in a U-shaped bend (see next page).
ATTENTION:
For a piping length of over 30 meters between the Hydraulic Power Supply Unit (HPSU) and
the Hydraulic Control Units at the actuators it could happened that the calculated stroke times
(for example 2 seconds) are not reached because the resistance of the pipework becomes
too large.

Instructions for installation of hoses
Correct installation increases the service life of hose assemblies:

1.) Under pressure, alterations of +2% to -4% can occur in the length of hose assemblies.
Hoses should therefore be installed with slack or curves.
2.) Hose assemblies should never be installed twisted (no torsion).
3.) Hose assemblies should not be bent excessively - use elbow fittings instead !
4.) Note minimum bend radius !
5.) If vertical displacement occurs, allow for amount of travel.
6.) Protect from external damage (use protective spirals).
WRONG BETTER RIGHT

Commissioning and
Maintenance Instruction
for
BOMAFA-Com.-No.: 1400655/2015
Order No.: B5V6275

Date: 2017-01-30
GENERAL INSTRUCTIONS FOR COMMISSIONING
READ THIS INSTRUCTION COMPLETELY BEFORE COMMISSIONING!
gram 1L 12728/A.
Before starting of operation, fill in Hydraulic Fluid (for example FYRQUEL EHC-N), but the
Hydraulic Fluid for the normal operation may be filled in after the flushing of the external pip-
ing.
filter MAX05 AT013. Fill up hydraulic fluid to the top of the oil level gauge (item 30) (approx.
450 litres).

Check and fill up the nitrogen pressure at the accumulator with the special filling and
test device (special tool, part of our delivery).
The operation instructions are included in this instruction and in the service case of the filling
and test device.
- for this service, the complete hydraulic system must be out of operation!
- the complete HPSU has to be switched off (power supply)
Make sure that no unallowed motor operation can be done.
For access to the accumulators inside the encapsulation of the HPSU, take off the side walls
just before beginning of this work and close the side walls tight again after finishing the work.
- the accumulators have to be released pressure less by manual operated shut off valves
(item 850 and 851).
Use nitrogen bottles with minimum 99.5% nitrogen only! Never use any other gas for
filling!
Never switch on the main pumps of the HPSU without sufficient nitrogen pressure.
Otherwise the bladder inside the accumulator will be damaged.
Page 1 / 9 Commissioning and maintenance HPSU 2017-01-30

The external hydraulic piping between the power pack and the hydraulic cylinders will be in-
stalled on site by others according to applicable Installation Instruction for Hydraulic Pipe-
work.
At least the external piping has to be pressure tested with the max. operating pressure
and cleaned by intensive flushing after installation! This pressure test should be con-
ducted by user before commissioning call.
Flushing of hydraulic components and pipework
The individual hydraulic components (HPSU, Hydraulic Control Units with actuators) were
already flushed in the factory of the company BOMAFA/asfa, before they were delivered.
So only the external hydraulic piping between the Hydraulic Power Supply Unit (HPSU) and
the Hydraulic Control Units at the actuators must be flushed on site.
The flushing fluid used should be the same hydraulic liquid (for example: FYRQUEL
EHC-N) that will be used for future operation of the unit.
Only in case of CS/MS piping material: During the intensive flushing procedure the oil
cleanness must become to Class 6 according to NAS 1638 (filter grade 10 µm for the op-
eration of proportional control valves).
In the following points the flushing procedure is described:

- First the hydraulic fluid for the flushing procedure (for example: FYRQUEL EHC-N) must
be filled into the HPSU (approx. 150 litres) by using a filling pump via the filling connection
at the return oil filter.
- Then the hoses at the end of the supply and return piping at the Hydraulic Control Units must
be connected (connectors are in our scope of supply) so that a continuous circulation can take
place from the HPSU above the pressure and the return pipeline back to the HPSU.
- The manual operated shut off valves (item 190 and 191) must be closed.
- Switch on both pump units MAX05 AP001 (item 70) and MAX05 AP002 (item 71) by means
of the corresponding motor power supply. The pump units must run during the complete
flushing procedure.
- When the accumulators (item 810 and 811) are filled and the pressure reached 160 bar,
the HPSU is ready for flushing.
- The best thing is to flush one after the other piping. So first the manual operated shut off
valve (item 190) must be opened. After opening the shut off valve the oil flows with a high
speed through the pipelines and there is a good cleaning for this pipeline. The flushing
time depends on the size and soiling of the pipelines, but one hour as a minimum.
- After flushing the pipeline the shut off valve (item 190) must be closed again.
- If the first pipeline is ready flushed, do the analogy service for the other pipeline with the
manual operated shut off valve (item 191).
- Having completed the flushing operation, exchange filter element, connect the hoses at
the end of the piping to the Hydraulic Control Units and open the manual operated shut off
valves (item 190 and 191).
- At last the hydraulic fluid must be removed from the oil tank and the oil tank must be
cleaned inside.
Functional check of the complete Hydraulic System
After the a. m. preparations are done, all function tests according to the separate Function
Test Report for the Hydraulic System have to be carried out.
During these tests, the interaction with the main control system DCS is very important.
The internal functions of the hydraulic power unit itself should be checked first.
The first actuation of the cylinders should be operated very careful and step by step
for each single valve by the control command signals from the DCS - refer to signal
I/O-list.
Now carry out the air venting of the external piping and the hydraulic cylinders accord-
ing to page 8.
Check the tightness of all fittings inside the power pack and the external piping and
fittings between the power pack and the hydraulic cylinders.
Work out all function tests according to the enclosed Function Test Report of the
HPSU.

GENERAL INSTRUCTIONS FOR MAINTENANCE AND SERVICE
gram 1L 12728/A.
1.) Hydraulic oil tank
Do the following checks in the first week after commissioning every day, then in the
first month after commissioning every week and after that every month:
- check if the oil level at sight glass MAX05 CL501 (item 30) is between min and max. level
- take a visual check for oil leakages at the oil tank, oil pan and all connections and fittings
- if necessary fill in Hydraulic Fluid (for example: FYRQUEL EHC-N),
by using a filling pump via the filling connection at the return oil filter.
Fill up hydraulic fluid to the top of the oil level sight glass
(refer to the following chapter oil filling)
After 6 month of operation:

- take an oil sample out of the running HPSU two times a year
- use a special bottle for oil samples (deliverable from oil distributors), connect the flexible
hose of the pressure gauge MAX05 CP501 (item 186) and fill the oil sample in the special
bottle for oil samples
- depending of the oil analysis (made by an oil laboratory) you will get the recommendation,
if the hydraulic fluid has to be changed or not
Complete oil change:

- for this service, the complete hydraulic system must be taken out of operation!
- a complete oil change must be done, when the oil sample analysis recommends this
- if a complete oil change is necessary, the complete HPSU has to be switched off (power
supply)
- the accumulators (item 810 and 811) have to be released pressure less by manual operat-
ed drain valves
- connect a flexible hose at oil drain valve (item 25) and drain the complete oil tank into a
waste oil barrel (total content approx. 450 litres)
- also the external pipes and all filter housings should be completely drained into a waste oil
barrel
- check the internal cleanness of the oil tank (inspection opening) and the filter housings
Oil filling
Fill in Hydraulic Fluid (for example FYRQUEL EHC-N) - never use any other fluid in the
HPSU.
filter MAX05 AT013. Fill up hydraulic fluid to the top of the oil level sight glass (approx. 450 l).

Don’t forget to close the manual operated drain valves (item 850 and 851) below the accumu-
lators again.
2.) Hydraulic cylinders, flexible hoses and pipes
Do the following checks in the first week after commissioning every day, then in the
first month after commissioning every week and after that every month:
- take a visual check for oil leakages at the hydraulic cylinders, the flexible hoses, the pipes
and fittings at the HPSU and from the HPSU to the hydraulic cylinders
- all parts have to be absolutely dry and free of any leakage outside
3.) Hydraulic Accumulators, Nitrogen Pressure
Do the following checks one week and one month after commissioning and then every
6 months:
- take a visual check for oil leakages at the hydraulic accumulators, safety valves (item 840
and 841) and all pipes and fittings
- all parts have to be absolutely dry and free of any leakage outside
Check and fill up the nitrogen pressure at the accumulator with the special filling and
test device (special tool, part of our delivery).
The operation instructions are included in this instruction and in the service case of the filling
and test device.
- for this service, the complete hydraulic system must be out of operation!
- the complete HPSU has to be switched off (power supply)
Make sure that no unallowed motor operation can be done.
- the accumulators have to be released pressure less by manual operated shut off valves
(item 830 and 831)
Never switch on the HPSU without sufficient nitrogen pressure. Otherwise the bladder
inside the accumulator will be damaged.

4.) High-Pressure Filters MAX05 AT011/AT012 (item 120/121), change of the filter element
Do the following service within one day after a filter clogging indicator of the High-
Pressure Filters gives signal!
A warning signal lamp on top of the filter housing turns from green to red and shows that the
filter element is clogged.
If high-pressure filter MAX05 AT011 (item 120) is clogged, switch off motor pump unit MAX05
AP001 (item 70) by means of the corresponding electric motor power supply. Make sure that
no unallowed motor operation can be done.
Connect the pressure test device MAX05 CP501 at the pressure test connection of the
pressure relief valve MAX05 AA091 (item 170). This must be pressure less before starting
the following work!
Close shut off valve MAX05 AA001 (item 194) and MAX05 AA002 (item 195). Screw off the
lower part of the filter housing and pour out the oil in a barrel for waist oil.
Pull out the old filter element. This can not be cleaned and has to be disposed to hazardous
waste.
Clean the lower part of the filter housing inside, check if all seals are in good condition and
installed correctly.
Use original packed and clean spare filter elements only. The filter fineness must be 10 µm.
Check if all seals are installed correctly and put in the new filter element.
Screw the lower part of the filter housing (only by hand - there is no tool necessary) to the
upper part again.
Clean the complete filter outside and wipe off any oil leakage.
Switch on pump unit MAX05 AP001 (item 70) by means of the corresponding motor power
supply again.
As soon as motor pump unit MAX05 AP001 (item 70) is in operation again, the gauge of
pressure test device MAX05 CP501 indicates the pump pressure. Check the tightness of the
pressure filter housing MAX05 AT011 (item 120) very exactly. If any leakage appears, switch
off motor pump unit MAX05 AP001 (item 70) again and check the reason for the leakage.
Replace the seals if necessary.
Remove the pressure test device MAX05 CP501 from the pressure test connection of the
pressure relief valve MAX05 AA091 (item 170).
If high-pressure filter MAX05 AT012 (item 121) is clogged, do the analogy service after
switching off motor pump unit MAX05 AP002 (item 71) and connect the pressure test device
MAX05 CP501 at pressure test connection of the pressure relief valve MAX05 AA092 (item
171).

5.) Hydraulic Return Oil Filter MAX05 AT013 / AT014, change of the filter element
Do the following service within one day after the filter clogging indicator MAX05 CP013
/ CP014 of the Hydraulic Return Oil Filter MAX05 AT013 / AT014 gives signal!
A warning signal lamp on top of the filter housing turns from green to yellow and shows that the
filter element is clogged.
To change the filter element of the return oil filter MAX05 AT013 the shut off valve MAX05
AA251 has to be closed.
Screw off the cover of the filter housing and pull out the old filter element. This can not be
cleaned and has to be disposed to hazardous waste.
Clean the cover of the filter housing inside, check if the seal (O-Ring) is in good condition and
installed correctly.
Use original packed and clean spare filter elements only. The filter fineness must be 10 µm.
Check if all seals are installed correctly and put in the new filter element.
Screw on the cover of the filter housing again. Clean the complete filter housing outside and
wipe off any oil leakage.
Open shut off valve MAX05 AA251 again and check the tightness of the return oil filter housing
MAX05 AT013 very exactly. If any leakage appears, close the shut off valve MAX05 AA251
again and check the reason for the leakage. Replace the seals if necessary.
If return oil filter MAX05 AT014 is clogged, do the analogy service after closing the shut off
valve MAX05 AA252.
6.) Fluid Regeneration Unit MAX05 AT016 / AT020, change of the filter / regeneration
cartridges
Do the following service within one day after the filter clogging indicator MAX05 CP506
of the filter housing MAX05 AT016 shows that the filter element is clogged (pressure > 2
bar) or the pressure switch MAX05 CP026 gives signal!
A warning signal or pressure switch MAX05 CP026 and the pressure gauge MAX05 CP506
on top of the filter housing MAX05 AT016 shows that the filter element is clogged (pressure >
2 bar).
To change the regeneration cartridge of the Regeneration Unit MAX05 AT020 the shut off
valves MAX05 AA261 and MAX05 AA262 have to be closed. Bypass valve MAX05 AA260
should be opened.
Open the drain valve at the button of the Regeneration Unit MAX05 AT020 and drain the
hydraulic fluid into a waist barrel. Open the cover of the Regeneration Unit housing, screw off
the fixing screw with the spring and pull out the old regeneration cartridge bag. This can not be
cleaned and has to be disposed to hazardous waste.
Clean the cover of the housing inside, check if the seal is in good condition and installed
correctly.
Use original packed and clean spare regeneration cartridge only. Put the new regeneration
cartridge in and fix it again with the spring and screw in the center.

Put on the cover of the regeneration unit housing again and fix it with the ring spanner. Clean
the complete filter housing outside and wipe off any oil leakage.
Open shut off valves MAX05 AA261 and MAX05 AA262 again, close bypass valve MAX05
AA260 and check the tightness of the regeneration unit housing MAX05 AT013 very exactly. If
any leakage appears, close the shut off valves MAX05 AA261 and MAX05 AA262 again and
check the reason for the leakage. Replace the seals if necessary.
If fine filter unit MAX05 AT016 is clogged, do the analogy service after closing the shut off
valves MAX05 AA261 and MAX05 AA260.
7.) Air Venting of the Hydraulic Cylinders and Pipes
The air venting has to be done during commissioning and has to be repeated some
times during the first week after commissioning.
Air inside the hydraulic cylinders and pipes will cause delayed response of the cylinder
movement and might be the reason for vibrations.
Only with completely air vented hydraulic cylinders and pipes you will get acceptable position
control functions of the valves.
At the highest points of the external pipes air venting couplings (pressure test couplings)
have to be installed (not in the scope of BOMAFA/asfa delivery).
Air venting couplings are also installed directly at both sides of the hydraulic cylinders.
Connect only the flexible hose (without pressure gauge) of the pressure test device MAX05
CP501 to the air venting couplings. Hold the free end of the flexible hose in an oil collecting
pot. While the flexible hose is screwed on to the air venting coupling, the coupling gets opened.
By switching on the respective solenoid valve or with the required input signal to the servo
valve the selected air venting valve will get under pressure.
ATTENTION: The hydraulic cylinders and valves will also be actuated in this way!
Keep the air venting valve opened until a clear, uninterrupted oil stream comes out of the free
end of the connected flexible hose.
As soon as the flexible hose is screwed off to the air venting coupling, the coupling gets closed
again.

8.) Oil Pressure Indication at the Pressure Test Couplings
During operation the oil pressure can be measured at the different pressure test cou-
plings, in the hydraulic power supply unit and at the cylinders, indicated in the hydrau-
lic circuit diagram.
Connect the pressure test device MAX05 CP501 (complete with pressure gauge) to the pres-
sure test couplings.
The pressure test couplings and air venting couplings are identical and will be used for both
purposes.
While the flexible hose is screwed on to the pressure test coupling, the coupling gets opened
and the pressure gauge shows the oil pressure at this point.
By switching on the respective solenoid valve or with the required input signal to the servo
valve the selected pressure test coupling will get under pressure.
ATTENTION: The hydraulic cylinders and valves will also be actuated in this way!
As soon as the flexible hose is screwed off to the pressure test coupling, the coupling gets
closed again.
Use the pressure test device MAX05 CP501 only during the a. m. pressure measurement and
disconnect it after that again. The pressure test device and the pressure gauge shall remain
pressure less during normal operation inside the hydraulic power unit.
For the oil pressure control by the DCS the pressure transmitters are in continuous operation.

Page 1/7
Material Safety Data Sheet
acc. to ISO/DIS 11014
Printing date 12/29/2005 Revision number: 1 Reviewed on 11/09/2005
1 Identification of substance
· Product details
· Trade name: FYRQUEL EHC-N
· Application of the substance / the preparation Fire-resistant hydraulic fluid
· Manufacturer/Supplier:
Supresta
420 Saw Mill River Road
Ardsley, NY 10502
USA
· Information department:
Product safety department.
1-914-269-5900 (9:00 am - 5:00 pm EDT)
· Emergency information:
Medical: PROSAR 1-888-875-1685 (24HRS)
Transportation: CHEMTREC 1-800-424-1685 (24 HRS)
2 Composition/Data on components
· Chemical characterization
· Description: Substance is a compound and/or mixture.
· Chemical Components:
25155-23-1 trixylyl phosphate 100%
· Carcinogenicity status (IARC, NTP, OSHA)
This product does not contain a listed carcinogen at a concentration of 0.1% or greater.
3 Hazards identification
· NFPA ratings (scale 0 - 4)
1
Health = 2
Fire = 1
2 0 Reactivity = 0
· HMIS-ratings (scale 0 - 4)
HEALTH 2 Health = 2
FIRE 1 Fire = 1
REACTIVITY 0 Reactivity = 0
· Additional information:
Caution:
May cause mild skin and eye irritation.
Inhalation of vapor or mist may cause respiratory tract irritation.
May cause nerve damage if inhaled, swallowed or absorbed through the skin.
May cause cholinesterase inhibition.
Repeated exposure may result in reproductive toxicity.
4 First aid measures

· After inhalation:
If inhaled, remove victim to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give
oxygen. Get medical attention.
(Contd. on page 2)
USA
DR
Page 2/7
Trade name: FYRQUEL EHC-N
(Contd. of page 1)
· After skin contact:
Immediately remove contaminated clothing and shoes. Under a safety shower, wash all affected areas with plenty
of soap and water for at least 15 minutes. Get medical attention immediately. Wash clothing before reuse.
Thoroughly clean or destroy contaminated shoes.
· After eye contact:
Immediately flush eyes with plenty of water for at least 15 minutes. Hold the eyelids apart during the flushing to
ensure rinsing of the entire surface of the eye and lids with water. Get medical attention if irritation develops and
persists.
· After swallowing:
Get medical attention by calling a physician or a poison control center immediately. Do not induce vomiting
unless directed to do so by medical personnel. If vomiting occurs, keep head below hips to reduce the risk of
aspiration. Never give anything by mouth to an unconscious person.
5 Fire fighting measures

· Suitable extinguishing agents:
Use water fog or spray, dry chemical, foam or carbon dioxide extinguishing agents.
· Special hazards caused by the material, its products of combustion or resulting gases:
Decomposition of this product under fire conditions can produce carbon monoxide, phosphorus oxides and
organic decomposition products.
· Protective equipment:
As in any fire, prevent human exposure to fire, smoke, fumes or products of combustion. Evacuate non-essential
personnel from the fire area. Firefighters should wear full-face, self contained breathing apparatus and
impervious protective clothing. If possible, move containers from the fire area. If not leaking, keep fire exposed
containers cool with a water fog or spray to prevent rupture due to excessive heat. High pressure water may
spread product from broken containers increasing contamination or fire hazard. Dike fire control water for later
disposal. Do not allow contaminated water to enter waterways.
· Additional information
This product is not defined as flammable or combustible. It is self-extinguishing once the source of ignition is
removed. The material is not sensitive to static discharge or physical impact. It may decompose under fire
conditions.
6 Accidental release measures

· Personnel-related safety precautions:
Isolate spill area and restrict nonessential personnel. All personnel involved in spill cleanup should follow
appropriate industrial hygiene practices (see Section 8).
Particular danger of slipping on leaked/spilled product.
· Measures for environmental protection:
Stop source of spill if possible. Dike area to prevent spill from spreading.
· Measures for cleaning/collecting:
Soak up liquid with a suitable absorbent such as clay, sawdust, or kitty litter. Sweep up absorbed material and
place in a chemical waste container for disposal. Cover spill area with a slurry of powdered household detergent
and water. Use stiff brush to work slurry into cracks and crevices. Allow to stand for 2-3 minutes, then flush with
water. Dike water for later disposal. Do not allow contaminated water to enter waterways or sewers.
USA
(Contd. on page 3)
DR
Page 3/7
(Contd. of page 2)
7 Handling and storage

· Handling:
· Information for safe handling:
Wear protective clothing including chemical goggles and/or a face shield and rubber gloves when handling this
product to avoid eye and skin contact. Handle in a well ventilated area. Avoid inhalation of vapor or mist. Wash
thoroughly after handling.
Containers should be located in an area where they can be rotated regularly (first in, first out) and visually
inspected for dents and bulging on a weekly basis.
Empty containers may retain product residues. Follow all warnings and precautions even after container is
empty.
· Information about protection against explosions and fires: The product is not flammable.
· Storage:
· Suggested Storage Conditions:
Store away from foodstuffs and animal feed. Containers should be stored in a cool, dry, well-ventilated area
away from flammable or oxidizing materials and sources of heat or flame.
· Information about storage in one common storage facility:
Prolonged storage at elevated temperatures under wet alkaline or acidic conditions should be avoided to assure
product integrity. Care should be taken to prevent moisture condensation in the container. Carbon steel is the
preferred material of construction for storage containers. The product is normally shipped in unlined tank cars,
trucks and drums.
· Further information about storage conditions:
The maximum storage temperature is 149 F or 65 C (Higher in absence of air/moisture).
At temperatures below 4.4 C (40 F), the viscosity characteristics are such that improved pumping rates may be
achieved by warming. Temperatures from 27 - 37.8 C (80 - 100 F) provide good flow rates.
This product can be stored and transported in equipment constructed of mild steel.
8 Exposure controls and personal protection

· Additional information about design of technical systems:
At elevated processing temperatures or in the event that use conditions generate airborne vapor, aerosol or mist,
the material should be handled in a well-ventilated area.
Where adequate ventilation is not available, respiratory protection should be used.
· Personal protective equipment:
· General protective and hygienic measures:
The primary routes of exposure to this product are skin contact and inhalation of mists or vapors.
· Breathing equipment:
Use a NIOSH-approved organic vapor/acid gas respirator (OVAG) with dust, mist and fume filters to reduce
potential for inhalation exposure if use conditions generate vapor, mist or aerosol and adequate ventilation (e.g.,
outdoor or well ventilated area) is not available. Where exposure necessitates a higher level of protection (e.g., if
breakthrough resulting in dizziness or numbness is experienced) use a NIOSH-approved, positive pressure,
pressure demand, air-supplied respirator.
· Protection of hands:
Skin contact with liquid or its aerosol should be prevented through the use of suitable protective clothing, gloves
and footware selected with regard for use condition exposure potential.
· Material of gloves Neoprene gloves
· Eye protection:
Eye contact with liquid or aerosol should be prevented through the use of chemical safety goggles and/or a face
shield selected with regard for use condition exposure potential.
(Contd. on page 4)
USA
DR
Page 4/7
(Contd. of page 3)
· Body protection:
Safety showers, with quick opening valves which stay open and eye wash fountains or other means of washing the
eyes with a gentle flow of cool to tepid tap water should be readily available in all areas where this material is
handled or stored. Water should be supplied through insulated and heat-traced lines to prevent freezeups in cold
weather. Long sleeved clothing may be used to minimize skin contact.
9 Physical and chemical properties

· General Information
Form: Liquid
Color: Clear, transparent
Odor: Nearly odorless
Melting point/Melting range: Not determined
Boiling point/Boiling range: 243 - 264°C (469 - 507°F) (@ 10 mmHg)
Pouring point < -17.77°C (< 0°F)
· Flash point: 246.1°C (475°F) (Seta cc)
· Ignition temperature: 565.55°C (1050°F)
· Auto igniting: Product is not selfigniting.
· Danger of explosion: Product does not present an explosion hazard.
· Vapor pressure at 20°C (68°F): 0.088 mmHg
· Density at 15.6°C (60°F): 1.15
· Solubility in / Miscibility with
Water at 25°C (77°F): 18.6 ug/l
· Viscosity:
Dynamic at 37.8°C (100°F): 220 SUS.
10 Stability and reactivity

· Thermal decomposition / conditions to be avoided:
This product is stable at ambient temperatures and atmospheric pressure. It is not self-reactive and is not
sensitive to static discharge or physical impact.
Prolonged storage at elevated temperatures (above 65.6 C; 150 F)should be avoided.
· Materials to be avoided:
This product is incompatible with strong oxidizers, strong acids and strong alkalis. It hydrolyzes slowly at
ambient temperatures in acidic or alkaline aqueous solutions.
· Dangerous reactions Hazardous polymerization is not expected to occur.
· Dangerous products of decomposition:
Under wet alkaline or neutral conditions this product hydrolyzes slowly and nonviolently.
11 Toxicological information
· Acute toxicity:
· LD/LC50 values that are relevant for classification:
25155-23-1 trixylyl phosphate
Oral LD50 11800 mg/kg (mouse)
(Contd. on page 5)
USA
DR
Page 5/7
(Contd. of page 4)
> 5000 mg/kg (rat)
Dermal LD50 > 2000 mg/kg (rabbit)
· Primary irritant effect:
· on the skin: May cause mild irritation.
· on the eye: May cause mild irritation.
· Sensitization: No sensitizing effects known.
· Ingestion: Repeated ingestion may cause cholinesterase inhibition.
· Inhalation:
Prolonged or repeated inhalation exposure may cause cholinesterase inhibition and respiratory tract irritation.
· Subchronic - Repeated dose effects:
In a subchronic toxicity study, rats that received daily oral doses of the product for three or more weeks showed a
reduction in plasma cholinesterase activity. Organ weight data indicated that the adrenals, testes, epididymides,
ovaries, heart, and liver were target organs. With the exception of the heart, microscopic examination of these
organs confirmed treatment-related changes. Neurotoxicity tests conducted during this study, including a
functional observation battery and motor activity assessment did not show any signs of neurotoxicity.
· Mutagenicity:
The product was evaluated in two mutagenicity assays, the Ames Test and Chinese Hamster Ovary Cell Assay for
Chromosomal Aberrations. The product did not demonstrate mutagenic activity in either test.
· Neurotoxicity:
Two neurotoxicity tests were conducted in adult hens to determine whether the product can cause delayed
peripheral neurotoxicity. In one study, the very high dose of 11.4 g/kg caused motor incoordination, 85% brain
cholinesterase inhibition, and 94% NTE inhibition, indicating that very high exposure to the product may result in
neurotoxicity. In a second study, conducted at lower doses, the product did not express neurotoxicity.
· Reproductive effects:
In a reproductive toxicity test, male and female rats received daily oral doses of the product for two weeks after
which they were mated. Although mating was successful, there was a treatment-related decrease in pregnancies
in the mid an high dose animals. While there were no pregnancies in the high dose animals, when the previously
treated animals were maintained without treatment for four weeks and then mated, all of the females became
pregnant. Thus the antifertility effect is fully reversible.
12 Ecological information
· Ecotoxical effects:
· Aquatic toxicity:
25155-23-1 trixylyl phosphate
EC50 (96-hr) > 1011 ug/l (Algae)
LC50 (48-hr) 60 ug/l (daphnia)
LC50 (96-hr) 1119 ug/l (Fathead minnow)
> 100 mg/l (Rainbow trout)
Practically non-toxic.
13 Disposal considerations
· Product:
· Recommendation:
Material that cannot be used or chemically reprocessed should be disposed of in accordance with all applicable
federal, state and local regulations.
This product, if unused, does not meet the EPA's criteria as either a listed or characteristic hazardous waste
under the Resource Conservations and Recovery Act (RCRA) as published in 40 CFR 261.
(Contd. on page 6)
USA
DR
Page 6/7
(Contd. of page 5)
· Uncleaned packagings:
· Recommendation:
Containers should be drained of residual material before disposal. Emptied containers should be disposed of in
accordance with all applicable laws and regulations.
Product containers designed for single use should be thoroughly emptied before disposal.
14 Transport information
· DOT regulations:
· Hazard class: 9
· Identification number: UN3082
· Packing group: III
· Proper shipping name (technical name): ENVIRONMENTALLY HAZARDOUS SUBSTANCE, LIQUID, N.O.S.
(Trixylenyl phosphate)
· Label 9
· Remarks: Not regulated for surface and air transport in non-bulk (< 119
gallons) packagings. This product contains trixylenyl phosphate which
is a Marine Pollutant as per 49 CFR 172.101, Appendix B.
· Maritime transport IMDG:
· Marine pollutant: Yes (P)
15 Regulations:
· Sara
· Section 355 (extremely hazardous substances):
None of the ingredients are listed.
· Section 313 (Specific toxic chemical listings):
This product does not contain a toxic chemical subject to the reporting requirements of section 313 of Title III of
the Superfund Amendments and Reauthorization Act of 1986 and 40 CFR part 372 (annual Toxic Chemical
Release Reporting).
· SARA Title III: Section 304 - CERCLA:
This product does not contain a hazardous substance regulated under Section 304 for emergency release
notification (CERCLA List).
· TSCA (Toxic Substances Control Act): Substance is listed.
· TSCA Section 12(b) - Export Notification:
This product does not contain any chemicals subject to Section 12(b) export notification.
· Proposition 65
· Chemicals known to cause cancer:
· Chemicals known to cause reproductive toxicity for females:
· Chemicals known to cause reproductive toxicity for males:
(Contd. on page 7)
USA
DR
Page 7/7
(Contd. of page 6)
· Chemicals known to cause developmental toxicity:
· OSHA status:
This product is considered to be a hazardous chemical under the OSHA Hazard Communication Standard (29
CFR 1910.1200)
· Resource Conservation and Recovery Act (RCRA):
This product is not considered to be a hazardous waste under RCRA (40 CFR 261).
· Canadian WHMIS Symbol(s):
· Canadian WHMIS Classification(s): D2A

· State Regulations:
· State Right-To-Know
25155-23-1 trixylyl phosphate 100%
16 Other information
This information in this material safety data sheet should be provided to all who will use, handle, store, transport
or otherwise be exposed to this product. All information concerning this product and/or suggestions for handling
and use contained herein are offered in good faith and are believed to be reliable as of the date of publication.
However, no warranty is made as to the accuracy of and/or sufficiency of such information and/or suggestions as
to the merchantability or fitness of the product for any particular purpose, or that any suggested use will not
infringe any patent. Nothing in here shall be construed as granting or extending any license under any patent.
Buyer must determine for himself, by preliminary tests or otherwise, the suitability of this product for his
purposes, including mixing with other products. The information contained herein supersedes all previously
issued bulletins on the subject matter covered. If the date of this document is more than three years old, call to
make certain that this sheet is current.
· Department issuing MSDS: Product safety department (Tel.: 914 269-5900)
USA
DR
HONEYWELL GLS PK 8150 1
Installation Instructions Ui 600V AC

lnstrucciones de InstalaciÓ n Ui 300V DC
lstruzioni per I'installazione UL EN50041
Notice d'installation EN60947-5-1
Betriebsanleitung CSA IEC 947-5-1
4iXbL-23>2.f4F
English Español Italiano

Rated thermal current Ith: 10A Corriente térmica Ith: 10A Corrente termica nominale Ith: 10A
1 AC Designation: A300/A600 1 Designación CA: A300/A600 1 Denominazione CA A300/A600
2 AC Utilization Category: AC15 2 Categoria de utilización: CA15 2 Categoria d’impiego CA CA15
3 DC Designation: Q300 3 Designación CC; Q300 3 Denominazione CC Q300
4 DC Utilization Category: DC13 4 Categoria de utilización: CC13 4 Categoria d’impiego CC CC13
Rated Impulse Withstand Uimp: 2500V DC Margen de impulso Uimp: 2500VCC Resistenza agli impulsi nominali Uimp: 2500V cc
Maximum fuse rating: Margen máximo del fusible: Valore nominale fusibili max:
10A quick acting Actuaión rápida 10A 10A a funzionamento rapido
Degree of protection: IP66, IP67 Grado de protección: IP66, IP67 Grado di protezione: IP66. IP67
NEMA/UL types 1,4,12,13 NEMA/UL tipos 1,4,12, 13 Tipi NEMA/UL 1, 4, 12, 13
Permissable Temperature Range: Rango permisible de temperatura: Campo di temperature ammesse:
Operating: -25 to + 85°C Operación: -25° to + 85°C durante il funzionamento: da-25° a + 85°C
Storage: -40 to + 120°C Almacenaje: -40° to + 120°C durante il magazzinaggio: da-40° a + 120°C
Conductor cross sections (screw connection): Secciones del conductor (conexión por tornillo): Sezioni trasversali conduttori (collegamento a vite):
Stranded: .75mm2 to 2.5mm2, 18 to 14 AWG Trenzado: .75mm² to 2.5mm², 18 a 14 AWG Treccia: da 0,75mm² a 2,5mm2, da 18 a 14 AWG
Solid: .75mm² to 1.5 mm², 18 to 16 AWG Compacto: .75mm2 to 1.5mm², 18 a 16 AWG Solido: da 0,75mm2 a 1,5mm², da 18 a 16 AWG
NOTE: Use 90°C wire when ambient is over 75°C. Nota: Use cable de 9O°C cuando la temperatura ambi- NOTA: Usare conduttore elettrico per 90°C quando la
Terminal Screws: M3 ente sobrepase los 75°C. temperatura ambientale supera i 75°C
Tightening torque: 80 N.cm (7 in.Lb.) Terminales de tornillo: M3 Viti morsetti: M3
Par de apriete: 80 N.cm (7" .libra) Coppia di serraggio: 80 N.cm
This product complies with Machinery Directive (89/
392/EEC as amended by Directive 91/368/EEC) and Este producto cumple con la Norma para la Maquinaria Questo prodotto è conforme alla "Direttiva sui macchi-
complies with EN60947-5-1. (89/392/CEE enmendada por la Norma 91/368/GEE) nari" (Direttiva CEE 89/392, successivamente modif-
y cumple con EN60947-5-1. icata dalla Direttiva CEE 91/368) ed è inoltre conforme
Carefully seal the cable entry to retain the degree of
protection rated. Thread sealant is recommended Sellar la entrada de cable para mantener el grado de alle norme EN60947-5-1.
on 1/2-14 NPT and PF-1/2 forms. protección. Se recomienda sellar la rosca en formatos Per assicurare il grado di protezione nominale, sigillare
½-14 NPT y PF ½. accuratamente I'entrata dei cavi. E' consigliato sigil-
Mount the switches using two screws at diagonal lante per filettature sui tipi NPT ½-14 e PF-½.
Montar los interruptores mediante dos tornillos en los
corners of the switch. Clearance holes are for M5 or ángulos diagonalmente opuestos del interruptor. Los
# 10 screws. Montare gli interruttori utilizzando due viti in corrispon-
taladros son para tornillos M5 ó n° 10. denza degli angoli sulle dragonali degli interruttori. Fori
Francais adatti a viti # 10 screws.
Courant nominal thermique: /th: = 10A
A300/A600 Deutsch
1 Designation AC:
2 Categorie d'utilisation: AC15 Thermischer Nennstrom Ith: 10A
3 Désignation DC: Q300 1 Wechselspannung Gebrauchskategorie
4 Categorie d'utilisation: DC13 A300/A600
Tension d'impulsion: Uimp: 2500 VDC 2 AC Utilization Category: AC15
lntensité maximum: 3 Gleichspannung Gebrauchskategorie 0300
Rupture brusque: 10A 4 DC Utilization Category: DC13
Degré de protection: IP66, IP67 Prüfspannung Uimp : 2500V
NEMA/UL types 1,4,12,13 Kurzschlußschutz:
Température ambiante: Max. 10 A flink
Fonctionnement: -25°C à + 85°C Schutzart: IP66, IP67
Stockage: -40°C à + 120°C NEMA/UL 1,4,12,13
Raccordement: section des conducteurs Temperaturbereich:
Fil torsadé: 0,75mm² à 2,5mm², 18 à 14 AWG Betriebstemperatur: -25... + 85°C
Fil simple: 0,75mm² à 1,5mm², 18 à 16 AWG Lagertemperatur: -40... + 120°C
REMARQUE: Utiliser un fil pour 90°C lorsque la tem- Anschlußquerschnitte (Schraubanschluß):
pérature ambiante est supérieure à 75°C. Verseilt: 0,75...2,5 mm², 18...14 AWG
Vis du bornier: M3 Massiv: 0,75...1.5mm2, 18...16AWG
Couple de serrage: 80N.cm (7 in.Lb.) HINWEIS: Bei Umgebungstemperatur über 75°C ei-
Ce produit est conforme aux prescriptions de la direc- nen 90°C Draht benutzen
tive sur les machines (89/392/CEE telle qu’amendée Anschlußschrauben: M3
par la directive 91/368/CEE) ainsi qu’à la norme Anzugsdrehmoment: 80 Ncm max.
EN60947-5-1. Dieses Produkt entspricht den Richtlinien für Maschi-
Pour respecter le degré de protection installer soig- nen (89/392/EEC und abgeänderten Richtlinien 91/
neusement le cable dans son presse étoupe. Presse- 368/EEC), sowie der Norm EN60947-5-1.
étoupe recommendé ½-14 NPT et PF-Forme ½ et PG Die Leitungseintührung ist sorgfältig zu schützen, da-
13,5 et 20mm. mit die o.a. Schutzart gewährleistet werden kann. Die
Pour le montage correct du fin de course serrage des Verwendung von Gewindedichtmitteln wird für ½-14
vis de fixation en diagonale. Les trous de fixation sont NPT and PF-½ empfohlen.
prévus pour recevoir des vis M5.
2 1 4 3
A300/A600 Q300
Ue le Make le Break Ue le
120 60 6 24 2.5
240 30 3 125 .55
380 19 1.9 250 .27
480 15 1.5
500 14 1.4
600 12 1.2
For application help: call 1-800-537-6945. Honeywell Sensing & Control 1

English
Español Italiano
Actuators
Actuadores Attuatori
5 Top Pin Plunger Head, Form B 5 Cabeza de émbolo, modelo B 5 Testa a pulsante superiore, tipo B
6 Top Roller Plunger Head, Form C 6 Cabeza de émbolo con rodillo, modelo C 6 Testa a pulsante con rotella superiore, tipo C
7 Top Roller Lever Head 7 Cabeza de palanca con rodillo 7 Testa a leva con rotella superiore
8 Wobble Stick Head 8 Cabeza de vástago flexible 8 Testa a levetta eccentrica
9 Roller Lever, Form A 9 Palanca con rodillo, modelo A 9 Leva con rotella, tipo A
10Rod Lever Adjustable, Form D 10 Palanca de varilla ajustable, modelo D 10 Leva con rotella regolabile, tipo D
11Adjustable Roller Lever 11 Palanca ajustable con rodillo 11 Leva con rotella regolabile
12Actuation by a straight rod 12 Actuation por varilla rigida 12 Attuazione tramite asta diritta
S -Pretravel to EN 50041 Precarrera según EN50041 Precorsa secondo EN50041
H -Differential Travel Carrera diferencial Corsa differenziale
• -Operate Point to EN 50041 Punto de operación EN50041 Punto operativo secondo EN50041
Fmin -Minimum Operating Force Minima fuerza de operación Forza operativa minima
Vmax Maximum Actuating Speed Velocidad máxima de actuación Velocità max di attuazione
› -Actuating Direction Dirección de actuación Direzione di attuazione
13 Basic Switches 13 Microrruptores básicos 13 lnterruttore base
Snap Action, 1 NO + 1 NC Ruptura brusca, 1 NC + 1 NA Funzionamento a scatto rapido, 1 NA + 1 NC
Slow Action, Break Before Make, 1 NO + 1 NC Acción lenta, ruptura antes de cierre, 1 NA + Funzionamento a scatto rapido, con interruz.
Slow Action, 1 NO + 1 NC with overlap 1 NA prima di chiusura, 1 NA + 1 NC
Snap Action DPDT Acción lenta, 1 NA + 1 NC con solape Funzionamento lento, 1 NA + 1 NC con so-
Snap Action Sequential DPDT Ruptura brusca DPDT vrapposizione
Snap Action Center Neutral DPDT Ruptura brusca secuencial DPDT DPDT con funzionamento a scatto rapido
14 Nominal contact travels and terminals Ruptura brusca centro neutro DPDT DPDT sequenziale con funzionamento a scat-
Contact Closed 14 Carreras nominales contacto y terminales to rapido
• Contact Open Contacto cerrado DPDT neutro centrale, funzionamento a scat-
Differential Travel Contacto abierto to rapido
** Forced Disconnect Travel Carrera differencial 14 Corse e termininali nominali dei contatti
•
Opening Position Carrera forzada de desconexión Contatto chiuso
15 Heads 5 through 11 can be repositioned at 90 Posición de apertura Contatto aperto
degree increments. Heads 5 through 11 are in- 15 Las cabezas 5 a 11 pueden reposicionarse en Corsa differenziale
terchangeable. incrementos de 90°. Las cabezas 5 a 11 son Corsa di disinserimento
Actuators 9 through 11 can be repositioned at 90 de- intercambiables. Posizione di apertura
gree increments in keys around shaft. Los actuadores 9 a 11 pueden reposicionarse 15 Le testine da 5 a 11 possono essere riposi-
en incrementos de 90° alrededor del eje. zionate a intervalli di 90°. Le testine da 5 a 11
Maintenance sono intercambiabili.
No maintenance is required. Mantenimiento GIi attuatori da 9 a 11 possono essere riposizionati a
No se requiere mantenimiento
intervalli di 90° nelle scanalature attorno all'albero.
Francais Manutenzione
Actioneurs: Non è richiesta alcuna manutenzione.
5 Tête à poussoir, Forme B Betätiger:
6 Tête à poussoir à galet, Forme C 5 Kuppenstössel, Form B Japanese
7 Tête à levier articulé à galet 6 Rollenstössel, Form C
8 Tête à tige flexible 7 Emzelhebel mit Rolle
9 Levier à galet, Forme A 8 Wendelfederstab
10 Levier à tige ajustable, Forme D 9 Einzelhebel mit Rolle, Form A
11 Levier à galet ajustable 10 Längenverstellbarer Stab, Form D
12 Actionnement avec une tige droite 11 Längenverstellbarer Einzelhebel mit Rolle
Précourse - EN50041 12 Betätigung durch geraden Stab
Course différentielle Vorlaufweg gemäß EN 50041
Point d'opération - EN50041 Differenzweg
Force minimum d'operation Schaltpunkt gemäß EN 50041
Vitesse maximum d'actuation Mindestbetätigungskraft
Direction de I'actuation Maximale Betätigungsgeschwindigkeit
13 Blocs contacts Betätigungsrichtung
Rupture brusque, 1 NO + 1 NC Schaltelemente:
Rupture lente, ouverture avant fermeture, Sprungschaltung 1S + 1Ö
1 NO + 1 NC Schleichschaltung, Offnen vor
Rupture lente, 1 NO + 1 NC chevauchants Schließen 1S + 1Ö
Rupture brusque bipolaire Schleichschaltung mit Überlappung 1S
Rupture brusque séquentielle bipolaire + 1Ö
Rupture brusque position neutre centrale Sprungschaltung DPDT
bipolaire Sprungschaltung DPDT, sequentiell
14 Fonctionnement des contacts Sprungschaltung DPDT,
Contact NF (normalement fermé) neutrale Mittelstellung
Contact NO (normalement ouvert) Schaltzustände und
Course différentielle AnschluBbezeichnungen:
Ouverture positive du contact Kontakte geschlossen
Position d'ouverture Kontakte geöffnet
15 Les têtes 5 à 11 peuvent être placés tous les Differenzweg
90°. Lers têtes 5 à 11 sont interchangeables. Mindestbetätigungsweg bis zur
Les actionneurs 9 à 11 peuvent ètre placés tous les Zwangsöffnung
90° autour de I'axe du levier. Offnungsstellung
Köpfe 5 bis 11 können in 4 mal 90° Schritten
Maintenance befestigt werden. Köpfe 5 bis 11 sind unter-
Aucune maintenance est nécessaire.
einander austauschbar.
Betätiger 9 bis 11 können in 90° Schritten form-
schlüssig montiert werden.
Wartung
Keine Wartung erforderlich.
2 Honeywell Sensing & Control For application help: call 1-800-537-6945.

For application help: call 1-800-537-6945. Honeywell Sensing & Control
For application help: call 1-800-537-6945. Honeywell Sensing & Control 5
HONEYWELL GLS Series PK 8150 1
Global Limit Switch

Drawings (dimensions in mm/in.)
Sensing & Control

a Honeywell Division
Helping you control your world

BTL7-A/C/E/G_ _ _-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S135/KA_ _
User's Guide
english
Micropulse Transducer - Rod Style
1 Notes to the user 4

1.1 Validity 4
1.2 Symbols and conventions 4
1.3 Scope of delivery 4
1.4 Approvals and markings 4
2 Safety 5
2.1 Intended use 5
2.2 General safety notes for the position measuring system 5
2.3 Explanation of the warnings 5
2.4 Disposal 5
3 Construction and function 6

3.1 Construction 6
3.2 Function 7
3.3 LED display 7
4 Installation and connection 8

4.1 Installation guidelines 8
4.2 Preparing for installation 8
4.3 Installing the transducer 9
4.3.1 Installation recommendation for hydraulic cylinders 9
4.4 Electrical connection 10
4.4.1 Connector type S32 10
4.4.4 Cable connection KA_ _ 11
4.5 Shielding and cable routing 11
5 Startup 12
5.1 Starting up the system 12
5.2 Operating notes 12
6 Calibration procedure 13
6.1 Calibration device 13
6.2 Programming inputs (not for BTL7-…-S135) 13
6.3 Calibration procedure overview 13
6.3.1 Teach-in 13
6.3.2 Adjusting 14
6.3.3 Online setting 14
6.3.4 Reset 14
6.4 Selecting the calibration procedure 14
6.5 Calibration procedure notes 15
2 english
7 Calibration using teach-in 16
8 Calibration using adjustment 17
9 Calibration using online setting 19
10 Resetting all values (reset) 20
11 Technical data 21
11.1 Accuracy 21
11.2 Ambient conditions 21
11.3 Supply voltage (external) 21
11.4 Output 21
11.5 Input 21
11.6 Dimensions, weights 22
12 Accessories 23
12.1 Magnets 23
12.2 Mounting nut 23
12.3 Connectors and cables 24
13 Ordering code 25
14 Appendix 26
14.1 Converting units of length 26
14.2 Part label 26
www.balluff.com english 3
1 Notes to the user
1.1 Validity The CE Mark verifies that our products

This guide describes the construction, function and setup meet the requirements of EU Directive
options for the BTL7 Micropulse Transducer with analog 2004/108/EC (EMC Directive).
interface. It applies to types
BTL7-A/C/E/G_ _ _-M_ _ _ _-A/B/Y/Z(8)-S32/S115/
S135/KA_ _ (see Ordering code on page 25).
The transducer meets the requirements of the following
generic standards:
The guide is intended for qualified technical personnel.
Read this guide before installing and operating the –– EN 61000-6-2 (noise immunity)
transducer. –– EN 61000-6-4 (emission)
Emission tests:
1.2 Symbols and conventions –– RF emission
Individual handling instructions are indicated by a EN 55016-2-3 Group 1,
preceding triangle. classes A
and B
►► Handling instruction 1
Noise immunity tests:
Handling sequences are numbered consecutively: –– Static electricity (ESD)
1. Handling instruction 1 EN 61000-4-2 Severity level 3
2. Handling instruction 2 –– Electromagnetic fields (RFI)
EN 61000-4-3 Severity level 3
Note, tip –– Electrical fast transients (burst)
This symbol indicates general notes. EN 61000-4-4 Severity level 3
–– Surge
These symbols indicate the buttons on the EN 61000-4-5 Severity level 2
1 2
calibration device.
–– Conducted interference induced by
Symbols of this type indicate the LED displays. high-frequency fields
–– Magnetic fields
1.3 Scope of delivery
–– BTL7 transducer More detailed information on the guidelines,

–– Calibration device approvals, and standards is included in the
–– Condensed guide declaration of conformity.
The magnets are available in various models

and must be ordered separately.
1.4 Approvals and markings
UL approval
File no.
E227256
US Patent 5 923 164
The US patent was awarded in connection with this
product.
4 english
2 Safety
2.1 Intended use 2.3 Explanation of the warnings

The BTL7 Micropulse Transducer, together with a machine Always observe the warnings in these instructions and the
controller (e.g. PLC), comprises a position measuring measures described to avoid hazards.
system. It is intended to be installed into a machine or
system. Flawless function in accordance with the The warnings used here contain various signal words and
specifications in the technical data is ensured only when are structured as follows:
using original BALLUFF accessories. Use of any other
components will void the warranty. SIGNAL WORD
Opening the transducer or non-approved use are not Hazard type and source
permitted and will result in the loss of warranty and liability Consequences if not complied with
claims against the manufacturer. ff Measures to avoid hazards
The individual signal words mean:

2.2 General safety notes for the position
measuring system NOTICE!
Installation and startup may only be performed by Identifies a hazard that could damage or destroy the
trained specialists with basic electrical knowledge. product.
Specialists are those who can recognize possible hazards
and institute the appropriate safety measures due to their DANGER
professional training, knowledge, and experience, as well The general warning symbol in conjunction with the
as their understanding of the relevant regulations signal word DANGER identifies a hazard which, if not
pertaining to the work to be done. avoided, will certainly result in death or serious
injury.
The operator is responsible for ensuring that local safety
regulations are observed.
In particular, the operator must take steps to ensure that a
defect in the position measuring system will not result in 2.4 Disposal
hazards to persons or equipment.
If defects and unresolvable faults occur in the transducer, ►► Observe the national regulations for disposal.
it should be taken out of service and secured against
unauthorized use.
3 Construction and function
Output signal with rising Error signal

characteristic: 100 %
0%
Null point End point
Mounting surface
B: 30-1 mm Damping zone 1)
Z: 2"-0.04" Nominal length =
BTL7...KA_ _
Measuring range
1)
BTL7...S115 BTL7...S32/S135
G
Ø D1
Magnet 2)
Thread size:
B: M18x1.5
Z: 3/4"-16UNF
Mounting surface
A: 30-1 mm
Y: 2"-0.04"
2) 1) Unusable area
Calibration device 1)
2) Not included in scope
of delivery
Version D1 G Thread size:

...-A/B/Y/Z-... 10.2 mm Thread A: M18x1.5
M4x4/6 deep Y: 3/4"-16UNF
...-A/B/Y/Z8-... 8 mm No thread
Fig. 3-1: BTL7...A/B/Y/Z(8)... transducer, construction and function
3.1 Construction Nominal length: Defines the available measuring range.

Rods with various nominal lengths from 25 mm to
Electrical connection: The electrical connection is made
7600 mm are available depending on the version:
via a cable or a connector (see Ordering code on page 25).
–– Ø 10.2 mm: Nominal length from 25 mm to 7600 mm
BTL housing: Aluminum housing containing the –– Ø 8 mm: Nominal length from 25 mm to 1016 mm
processing electronics.
Damping zone: Area at the end of the rod that cannot be
Mounting thread: The transducers with Ø 10.2 mm have used for measurements, but which may be passed over.
an additional thread at the end of the rod to support larger
nominal lengths. We recommend assembling this Calibration device: Additional device for calibrating the
transducer on the mounting thread: transducer.
–– BTL7-…-A/B: M18×1.5
–– BTL7-…-Y/Z: 3/4"-16UNF
Magnet: Defines the position to be measured on the

waveguide. Magnets are available in various models and
must be ordered separately (see accessories on page 23).
6 english
3 Construction and function (continued)
3.2 Function 3.3 LED display

The Micropulse Transducer contains the waveguide which LED 1 LED 2
is protected by an outer stainless steel tube (rod). A
magnet is moved along the waveguide. This magnet is
connected to the system part whose position is to be
determined.
The magnet defines the position to be measured on the

waveguide.
An internally generated INIT pulse interacts with the

magnetic field of the magnet to generate a torsional wave
in the waveguide which propagates at ultrasonic speed.
The component of the torsional wave which arrives at the

end of the waveguide is absorbed in the damping zone to Fig. 3-2: Position of the BTL7 LED displays
prevent reflection. The component of the torsional wave
which arrives at the beginning of the waveguide is In normal operation LED 1 indicates the
converted by a coil into an electrical signal. The travel time operating states of the transducer. Both LEDs
of the wave is used to calculate the position. Depending together are used for displaying additional
on the version, this information is made available as a information in programming mode
voltage or current output with a rising or falling gradient. (see page 16 ff).
LED 1 LED 2 Operating state

Green Off Normal function
Magnet is within the measuring range.
Flashing Measuring range left
red Magnet is outside the measuring range.
Red Error
No magnet or magnet outside the limits.
Tab. 3-1: LED displays in normal operation
4 Installation and connection
4.1 Installation guidelines 4.2 Preparing for installation

Non-magnetizable material Installation note: We recommend using non-
magnetizable material to mount the transducer and
Non-magnetizable material magnet.
min. Ø D21)
Horizontal assembly: If installing horizontally with
nominal lengths > 500 mm, we recommend tightening the
outer rod at the end (only possible with Ø 10.2 mm) or
supporting it.
Magnet
1)
Min. Ø D2 = Minimum diameter of the bore (see Tab. 4-1)
Hydraulic cylinder: If installed in a hydraulic cylinder,
ensure that the minimum value for the bore diameter of the
Fig. 4-1: Installation in non-magnetizable material support piston is complied with (see Tab. 4-1).
Magnetizable material Mounting hole: The transducer comes with an M18×1.5

If using magnetizable material, the transducer must be (ISO) or 3/4"-16UNF (SAE) mounting thread. Depending on
protected against magnetic interference through suitable the version, a mounting hole must be made before
measures (e.g. spacer ring made of non-magnetizable assembly.
material, a suitable distance from strong external magnetic
fields).
Magnet Spacer ring made of non-magnetizable

material
Fig. 4-3: Mounting hole M18x1.5 per ISO 6149 O-ring 15.4x2.1

min. Ø D21)
Magnet Spacer ring made of non-magnetizable

material
1)
Min. Ø D2 = Minimum diameter of the bore (see Tab. 4-1)
Fig. 4-2: Installation in magnetizable material
Tube diameter Bore diameter D2

10.2 mm At least 13 mm Fig. 4-4: Mounting hole 3/4” 16UNF per SAE J475 O-ring 15.3x2.4
8 mm At least 11 mm
Magnet: Various magnets are available for the BTL7
Tab. 4-1: Bore diameter if installed in a h
ydraulic cylinder transducer (see Accessories on page 23).
8 english
4 Installation and connection (continued)
4.3 Installing the transducer The sliding element can be screwed on or bonded.
►► Secure the screws so they cannot be loosened or lost.
►► Select a suitable adhesive.
NOTICE!
Slide surface
Interference in function Flow gap
Piston rod
Improper installation can compromise the function of the
BTL outer rod
transducer and result in increased wear.
ff The mounting surface of the transducer must make
full contact with the supporting surface.
ff The bore must be perfectly sealed (O-ring/flat seal).
Slide element
►► Make a mounting hole with thread (possibly with
countersink for the O-ring) acc. to Fig. 4-3 or Fig. 4-4.
Fig. 4-6: Detailed view and top view of sliding element
►► Screw the transducer with mounting thread into the
mounting hole (max. torque 100 Nm).
There must be a gap between the sliding element and
►► Install the magnet (accessories). piston bore that is sufficiently large for the hydraulic oil to
►► For nominal lengths > 500 mm: Tighten the outer rod flow through.
at the end (only possible with Ø 10.2 mm) or support it.
Options for fixing the magnet:
Suitable nuts for the mounting thread are –– Screws
available as accessories (see page 23). –– Threaded ring
–– Press fitting
–– Notches (center punching)
4.3.1 Installation recommendation for hydraulic
cylinders
If installed in a hydraulic cylinder, the magnet
If you seal the hole with a flat seal, the max. operating should not make contact with the outer rod.
pressure will be reduced in accordance with the larger
pressurized surface.
If installing horizontally in a hydraulic cylinder (nominal The hole in the spacer ring must ensure optimum guidance
lengths > 500 mm), we recommend affixing a sliding of the outer rod by the sliding element.
element to protect the rod end from wear.
Magnet
Fixing of magnet
Dimensioning of the detailed solutions is the
responsibility of the cylinder manufacturer.
The sliding element material must be suitable for the

appropriate load case, medium used, and application
temperatures. E.g. Torlon, Teflon or bronze are all possible
materials.
Slide element
Magnet
Spacer ring
Fig. 4-7: Fixing the magnet
Fig. 4-5: Example 1, transducer installed with sliding element An example of how to install the transducer with a
supporting rod is shown in Fig. 4-8 on page 10.
4.4 Electrical connection

Magnet Depending on the model, the electrical connection is made
(e.g. BTL-P-1028-15R) using a cable (BTL7...-KA) or a connector (BTL7...-S32,
BTL7...-S115, BTL7...-S135).
The connection or pin assignments for the respective
version can be found in Tables 4-2 to 4-5.
Note the information on shielding and cable

routing on page 11.
Supporting rod made of non-magnetizable material
Fig. 4-8: Example 2, transducer installed with supporting rod
4.4.1 Connector type S32
Pin -A_10 -G_10 -C_00 -C_70 -E_00 -E_70

1)
1 Not used 0 to 20 mA 20 to 0 mA 4 to 20 mA 20 to 4 mA
2 0V
3 10 to 0 V 10 to -10 V Not used1) Fig. 4-9: Pin assignment of S32 (view of
connector pins of transducer),
4 La (programming input) 8-pin M16 circular plug
5 0 to 10 V -10 to 10 V Not used1)
8 Lb (programming input)
BTL7-_1_ _-... BTL7-_5_ _-...
6 GND2) GND2)
7 20 to 28 V 10 to 30 V
1)
Unassigned leads can be connected to the GND on the controller side but not to the shield.
2)
Reference potential for supply voltage and EMC-GND.
Tab. 4-2: Connection assignment BTL7...-S32
Pin -A_10 -G_10 -C_00 -C_70 -E_00 -E_70

1 0 V (pin 3)
2 0 V (pin 5)
4 La (programming input) 8-pin M12 circular plug
5 0 to 10 V -10 to 10 V 0 to 20 mA 20 to 0 mA 4 to 20 mA 20 to 4 mA
8 Lb (programming input)
BTL7-_1_ _-... BTL7-_5_ _-...
6 GND 2)
GND2)
7 20 to 28 V 10 to 30 V
1)
2)
10 english
Pin -A_10 -G_10 -C_00 -C_70 -E_00 -E_70

1 0 to 10 V -10 to 10 V 0 to 20 mA 20 to 0 mA 4 to 20 mA 20 to 4 mA
2 0 V (pin 1)
1)
4 0 V (pin 3) Not used 6-pin M16 circular plug
BTL7-_1_ _-... BTL7-_5_ _-...
5 20 to 28 V 10 to 30 V
2)
6 GND GND2)
1)
2)
4.4.4 Cable connection KA_ _
Cable color -A_10 -G_10 -C_00 -C_70 -E_00 -E_70

YE yellow Not used1) 0 to 20 mA 20 to 0 mA 4 to 20 mA 20 to 4 mA
GY gray 0V
PK pink 10 to 0 V 10 to -10 V Not used1)
RD red La (programming input)
GN green 0 to 10 V -10 to 10 V Not used1)
WH white Lb (programming input)
BTL7-_1_ _-... BTL7-_5_ _-...
2)
BU blue GND GND2)
BN brown 20 to 28 V 10 to 30 V
1)
2)
Tab. 4-5: Connection assignment BTL7...-KA_ _
4.5 Shielding and cable routing Magnetic fields

The position measuring system is a magnetostrictive
Defined ground! system. It is important to maintain adequate distance
The transducer and the control cabinet must be between the transducer cylinder and strong, external
at the same ground potential. magnetic fields.
Cable routing
Shielding Do not route the cable between the transducer, controller,
To ensure electromagnetic compatibility (EMC), observe and power supply near high voltage cables (inductive stray
the following: noise is possible).
–– Connect the transducer and controller using a shielded The cable must be routed tension-free.
cable.
Shielding: Copper filament braided, at least 85% Bending radius for fixed cable
coverage. The bending radius for a fixed cable must be at least five
–– Connector version: Shield is interally connected to times the cable diameter.
connector housing. Cable length
–– Cable version: On the transducer side, the cable
shielding is connected to the housing. BTL7-A/G Max. 30 m1)
Ground the cable shielding on the controller side BTL7-C/E Max. 100 m1)
(connect with the protective earth conductor).
Tab. 4-6: Cable lengths BTL7
1)
Prerequisite: Construction, shielding and routing preclude the effect of any
external noise fields.
5 Startup
5.1 Starting up the system
Danger
Uncontrolled system movement
When starting up, if the position measuring system is
part of a closed loop system whose parameters have not
yet been set, the system may perform uncontrolled
movements. This could result in personal injury and
equipment damage.
ff Startup must be performed only by trained technical
personnel.
ff Observe the safety instructions of the equipment or
system manufacturer.
1. Check connections for tightness and correct polarity.

Replace damaged connections.
2. Turn on the system.
3. Check measured values and adjustable parameters
and readjust the transducer, if necessary.
Check for the correct values at the null point

and end point, especially after replacing the
transducer or after repair by the manufacturer.
5.2 Operating notes
–– Check the function of the transducer and all associated

components on a regular basis.
–– Take the position measuring system out of operation
whenever there is a malfunction.
–– Secure the system against unauthorized use.
12 english
6 Calibration procedure
6.1 Calibration device 6.3 Calibration procedure overview

The calibration device is an additional device for calibrating
the transducer.
6.3.1 Teach-in
►► Before calibrating: Place the calibration device on the
connection side of the transducer. The factory set null point and end point is replaced by a
►► When finished with calibration: Remove the calibration new null point and end point.
device to prevent changes.
►► Keep the calibration device for later use. The detailed procedure for teach-in is described
on page 16.
Automatic deactivation!
If the buttons on the calibration device are not Steps:
pressed for approx. 10 min., programming ►► Move magnet to the new zero position.
mode is automatically ended. ►► Read new null point by pressing the buttons.
New null point
Fa
llin
g
Before
ing
Ris After
Button 1 (blue) Button 2 (gray)
Fig. 6-1: Calibration device in place Fig. 6-2: Reading new null point (offset shift)
►► Move magnet to the new end position.

6.2 Programming inputs (not for BTL7-…-S135)
►► Read new end point by pressing the buttons.
Instead of the calibration device, the programming inputs
may also be used for setting.
–– La corresponds to button 1,
–– Lb corresponds to button 2,
–– Programming input at 20 to 28 V (BTL7-_1_ _-...) or 10
to 30 V (BTL7-_5_ _-...) corresponds to button
depressed (high active). New end point
Automatic deactivation! Before

If no signals are sent over the programming
inputs for approx. 10 min., programming mode
is automatically ended. After
New measuring length 100%
Fig. 6-3: Reading new end point (changing the output gradient)
6 Calibration procedure (continued)
6.3.2 Adjusting 6.3.3 Online setting
The detailed procedure for adjustment is The detailed procedure for online setting is
described on page 17 ff. described on page 19.
A new start and/or end value is adjusted. This is Setting start and end values while the system is running.
recommended when the magnet cannot be brought to the
null point or end point.
Steps 6.3.4 Reset

►► Move magnet to the new start position.
The detailed procedure for the reset is
►► Set the new start value by pressing the buttons. described on page 20.
Restoring the transducer to its factory settings.
6.4 Selecting the calibration procedure
New start value

Buttons inactive
Before 1 / 2
1
1 + 2
After
Buttons active
Null point 1 1 + 2
1 2
Fig. 6-4: Adjusting new start position (offset shift)

Reset
►► Move magnet to the new end position.
Teach-in Adjusting
►► Set the new end value by pressing the buttons.
1 2 1 2
Null End Null End

New end value point point point point
Buttons inactive
Before 1
1 2
1 + 2
1 2 + 1
1
After
Buttons active
End point
Fig. 6-5: Adjusting new end position (changing the output gradient) Online Online
setting setting
Fig. 6-6: Selecting the calibration procedure
14 english
6 Calibration procedure (continued)
6.5 Calibration procedure notes
Prerequisites
–– The calibration device is in place or the programming
inputs are connected.
–– The transducer is connected to the system controller.
–– Voltage or current values from the transducer can be
read (using a multimeter or the system controller).
Values for zero and end point

–– Any desired position of the magnet can be used as the
zero or end point. However, the zero and end points
may not be reversed.
–– The absolute zero and end points must lie within the
minimum or maximum limits of what can be output
(see value table).
–– The distance between the null point and end point
must be at least 4 mm.
The last set values are always saved, regardless

of whether the setting was ended using the
buttons, the programming inputs or
automatically after 10 min. have expired.
Value table for teach-in and adjustment

The following examples refer to transducers
with 0 to 10 V or 4 to 20 mA output.
For all other versions, use the values in the
value table below.

Output Linear Unit Min. Null Identification Identification End Max. Error
gradient transducer value value for adjustment for teach-in value value value
Rising BTL7-A… V −0.5 0 2.0 4.0 +10.0 +10.5 +10.5
BTL7-G… V −10.5 −10.0 2.0 4.0 +10.0 +10.5 +10.5
BTL7-C… mA 0 0 6.0 12.0 20.0 20.4 20.4
BTL7-E… mA 3.6 4.0 6.0 12.0 20.0 20.4 3.6
Falling BTL7-A… V +10.5 +10.0 8.0 6.0 0 −0.5 −0.5

BTL7-G… V +10.5 +10.0 −2.0 −4.0 −10.0 −10.5 −10.5
BTL7-C… mA 20.4 20.0 14.0 8.0 0 0 20.4
BTL7-E… mA 20.4 20.0 14.0 8.0 4.0 3.6 3.6
Tab. 6-1: Value table for teach-in and adjustment
7 Calibration using teach-in
NOTICE!
Interference in function
Teach-in while the system is running may result in LED display Displayed values (example)
malfunctions.
ff Stop the system before performing teach-in.
LED1 LED2 At 0 to 10 V At 4 to 20 mA
Initial situation:
–– Transducer with magnet within measuring range 5.39 V 9.15 mA
1. Activate buttons
►► Hold down any button for at least 3 s. >3s 1 2 5.39 V 9.15 mA
►► Release button. <1s
►► Within 1 s, hold down and simultaneously for at
least 3 s. >3s 1 2
⇒⇒ Output indicates error value.

10.50 V 3.60 mA
⇒⇒ Buttons are activated.
If an error or an interruption occurs while
activating the buttons, allow a wait time of 12 s
before retrying.
2. Select teach-in
►► Hold down for at least 2 s. > 2 s 1
⇒⇒ Indication for "Teach-in" is displayed. 4.00 V 12.00 mA
►► Release .
⇒⇒ Current position value is displayed. 5.39 V 9.15 mA
3. Set null point

►► Bring magnet to the new null point. 1.04 V 4.82 mA
►► Hold down for at least 2 s. > 2 s 1 0.00 V 4.00 mA
⇒⇒ The new null point is set. 0.00 V 4.00 mA
4. Set end point

►► Bring magnet to the new end point. 9.89 V 19.13 mA
►► Hold down for at least 2 s. > 2 s 2 10.00 V 20.00 mA
⇒⇒ The new end point is set. 10.00 V 20.00 mA
5. Exit teach-in and deactivate buttons
►► Hold down and simultaneously for at least 6 s. > 6 s 1 2

10.50 V 3.60 mA
►► Briefly press or (< 1 s). < 1 s 1 2
⇒⇒ Buttons are deactivated.
LED legend: LED not on LED flashing green
LED green
LED 1 and LED 2 flashing green-green in
LED red alternation
16 english
8 Calibration using adjustment
NOTICE!
Adjustment while the system is running may result in LED display Displayed values (example)
malfunctions.
ff Stop the system before performing adjustment. LED1 LED2 At 0 to 10 V At 4 to 20 mA
Initial situation:
–– Transducer with magnet within measuring range 5.39 V 9.15 mA
1. Activate buttons
►► Within 1 s, hold down and simultaneously for at
>3s 1 2
least 3 s.
10.50 V 3.60 mA
before retrying.
2. Select adjustment
⇒⇒ Indication for "Adjustment" is displayed. 2.00 V 6.00 mA
►► Release .
3. Adjust start value

►► Bring magnet to start position. 1.04 V 4.82 mA
⇒⇒ Indication for "Adjust start value" is displayed. 1 0.00 V 4.00 mA
►► Adjust start value. 1
⇒⇒ The start value can be changed using and 1).
1.04 V 4.82 mA
The gradient of the output remains constant (see
page 14). 1.00 V 4.40 mA
2
2
►► Exit calibration procedure: Press and for no
more than 2 s. < 2 s 1 2
⇒⇒ Set position value is saved. 1.00 V 4.40 mA
Adjust end value

(see page 18)
1) Briefly press button: Current value is increased or LED legend: LED not on
decreased by approx. 1 mV or 1 mA.
If a button is held down longer than 1 s, the step
LED green LED 1 and LED 2 flashing green-red in alternation
interval is increased.
LED flashing green LED 1 and LED 2 flashing red-red in alternation
8 Calibration using adjustment (continued)
Adjust
start value LED display Displayed values (example)
(see page 17)
4. Adjust end value
►► Bring magnet to end position. 9.89 V 19.13 mA
⇒⇒ Indication for "Adjust end value" is displayed. 1 10.00 V 20.00 mA
►► Adjust end value 1
⇒⇒ The end value can be changed using 9.89 V 19.13 mA
and 1). The gradient of the output
is changed, but the zero value remains 9.00 V 19.00 mA
unchanged (see page 14). 2
2
►► Exit calibration procedure: Press and for no

more than 2 s. < 2 s 1 2
⇒⇒ Set position value is saved. 9.00 V 19.00 mA
Check values
The settings for the start value and end
value have a mutual effect depending
on the measuring position.
Repeat steps 3 and 4 until the desired
values are exactly set.
5. Exit adjustment and deactivate buttons

►► Hold down and simultaneously for at least 6 s. > 6 s 1 2
⇒⇒ Output indicates error value. 10.50 V 3.60 mA
►► Briefly press or (< 1 s). < 1 s 1 2
⇒⇒ Buttons are deactivated.
⇒⇒ Current position value is displayed.
9.00 V 19.00 mA
1) Briefly press button: Current value is increased or LED legend: LED not on
decreased by approx. 1 mV or 1 mA.
LED green LED 1 and LED 2 flashing red-green in alternation
LED flashing green LED 1 and LED 2 flashing red-red in alternation
18 english
9 Calibration using online setting
In online setting the system is not shut down. The start and
NOTICE! end values are set online.
Interference in function Maximum setting range for each calibration
procedure:
Changing the transducer output signal may result in
Start value: ±25% of present stroke
personal injury and equipment damage if the system is
End value: ±25% of present output value
ready for operation.
If the desired value cannot be attained in the first
ff Persons must keep away from the system's calibration procedure (max. setting range exceeded), the
hazardous zones. calibration procedure must be started again.
1. Set start value online: LED display Displayed values (example)

►► Move the system so that the magnet is in the start LED1 LED2 At 0 to 10 V At 4 to 20 mA
position.
5.39 V 12.62 mA
►► Hold down for at least 3 s. >3s 1 5.39 V 12.62 mA

►► Hold down and additionally press +
for at least 3 s. >3s 1 2
⇒⇒ Buttons are activated. 1 5.39 V 12.62 mA

►► Set start value.
1
⇒⇒ Using and , you can change the start value
within the permissible setting range1). The gradient 4.84 V 11.72 mA
of the output remains constant (see page 14).
2
►► Exit setting (do not press a button for at least 15 s). 2
⇒⇒ The start value is saved, the buttons are 4.84 V 11.72 mA
deactivated.
After each calibration procedure you must wait for the
lockout time of 15 s. This also applies to switching
between the start value and end value setting.
2. Set end value online: LED display Displayed values (example)

►► Move the system so that the magnet is in the end
position. 8.72 V 17.95 mA
►► Hold down for at least 3 s. >3s 2 8.72 V 17.95 mA

►► Hold down and additionally press +
⇒⇒ Buttons are activated. 8.72 V 17.95 mA

►► Set end value. 1
⇒⇒ Using and , you can change the end value 1
within the permissible setting range1). The gradient
of the output is changed, but the zero value 9.49 V 19.18 mA
remains unchanged (see page 14).
2
►► Exit setting (do not press a button for at least 15 s). 2
⇒⇒ The end value is saved, the buttons are
deactivated. 9.49 V 19.18 mA
1) Briefly press button: Current value is increased or

decreased by approx. 1 mV or 1 mA. LED legend: LED not on LED 1 and LED 2 flashing green-red in alternation
LED green LED 1 and LED 2 flashing red-green in alternation
10 Resetting all values (reset)
NOTICE!
Resetting the values while the system is running may
result in malfunctions.
ff Stop the system before performing the reset.
The reset function can be used to restore all the settings

to the factory settings. For a reset the magnet may also
be located outside the measuring range.
LED display Displayed values (example)

5.39 V 10.80 mA
1. Activate buttons
►► Within 1 s, hold down and simultaneously

10.50 V 3.60 mA

before retrying.
2. Reset
►► Hold down and for at least 6 s. > 6 s 1 2
⇒⇒ Output indicates zero value. 0.00 V 4.00 mA
⇒⇒ All values are reset.
►► Release buttons.
⇒⇒ Current position value is displayed.
⇒⇒ Buttons are locked. 8.43 V 15.67 mA
LED legend: LED not on
LED green LED flashing green
LED 1 and LED 2 flashing green-red simultane-

ously
20 english
11 Technical data
11.1 Accuracy 11.3 Supply voltage (external)

The specifications are typical values for BTL7-A/C/E/G... at Voltage, stabilized:
24 V DC and room temperature, with a nominal length of
500 mm in conjunction with the BTL‑P‑1013‑4R, BTL7-_1_ _-... 20 to 28 V DC
BTL‑P‑1013‑4S, BTL‑P‑1012‑4R, BTL‑P‑1014‑2R or BTL7-_5_ _-... 10 to 30 V DC
BTL‑P‑0814‑GR‑PAF magnet. Ripple ≤ 0.5 Vss
The BTL is fully operational immediately, with full accuracy
after warm-up. Current draw (at 24 V DC) ≤ 150 mA
Inrush current ≤ 500 mA/10 ms
For special versions, other technical data may Reverse polarity protection Up to 36 V
apply.
Overvoltage protection Up to 36 V
Special versions are indicated by the suffix -SA
on the part label. Dielectric strength 500 V AC
(GND to housing)
Repeat accuracy
Voltage, typical ±10 µm 11.4 Output
Current, typical ±5 µm
BTL7-A… Output voltage 0 to 10 V and 10 to 0 V
Sampling rate
Load current ≤ 5 mA
Dependent on nominal length 250 µs to 5.5 ms
At nominal length = 500 mm 500 µs BTL7-C… Output current 0 to 20 mA/20 to 0 mA
Load resistance ≤ 500 ohms
Non-linearity at
Nominal length ≤ 500 mm ±50 µm BTL7-E… Output current 4 to 20 mA/20 to 4 mA
Nominal length > 500 to ±0.01% FS Load resistance ≤ 500 ohms
≤ 5500 mm BTL7-G… Output voltage −10 to 10 V and 10 to −10 V
Nominal length > 5500 mm ±0.02% FS Load current ≤ 5 mA
Temperature coefficient Short circuit resistance Signal cable to 36 V
(nominal length = 500 mm, magnet in Signal cable to GND
the middle of the measuring range) ≤ 30 ppm/K
Max. detectable speed 10 m/s
11.5 Input
11.2 Ambient conditions Programming inputs La, Lb: High-active

BTL7-_1_ _-... 20 to 28 V DC
Operating temperature −40°C to +85°C BTL7-_5_ _-... 10 to 30 V DC
Storage temperature −40°C to +100°C
Overvoltage protection up to 36 V
Relative humidity < 90%, non-condensing
Outer rod pressure rating
(when installed in hydraulic
cylinders)
For Ø 8 mm < 250 bar
For Ø 10.2 mm < 600 bar
Shock rating 150 g/6 ms
per EN 60068-2-271)
Continuous shock 150 g/2 ms
per EN 60068-2-291)
Vibration 20 g, 10 to 2000 Hz
per EN 60068-2-61)
Degree of protection per
IEC 60529
Connector S32/S115/ IP67
S135 (when attached)
Cable KA_ _ IP681)
1)
Individual specifications as per Balluff factory standard
11 Technical data (continued)
11.6 Dimensions, weights
Diameter of outer rod 8 mm or 10.2 mm

Nominal length
For Ø 8 mm 25 to 1016 mm
For Ø 10.2 mm 25 to 7600 mm
Weight (depends on Approx. 2 kg/m
length)
Housing material Anodized aluminum
Outer rod material Stainless steel 1.4571
Outer rod wall thickness
For Ø 8 mm 0.9 mm
For Ø 10.2 mm 2 mm
Young's modulus Approx. 200 kN/mm2
Housing mounting via M18×1.5 or 3/4"-16UNF
threads
Tightening torque Max. 100 Nm
1)
Cable diameter 6.7 mm
Permissible cable
bending radius1)
Fixed routing ≥ 35 mm
Movable ≥ 105 mm
1)
For BTL7-...-KA_ _
22 english
12 Accessories
Accessories are not included in the scope of delivery and BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R,
must be ordered separately. BTL-P-1014-2R:
Weight: Approx. 10 g
12.1 Magnets
Housing: Anodized aluminum
BTL-P-1013-4R
BTL-P-0814-GR-PAF:
Weight: Approx. 2 g
Housing: Ferrite bound in PA
The scope of delivery for

BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R
magnets includes:
BTL-P-1013-4S Spacer: 8 mm, material: polyoxymethylene
(POM)
BTL5-P-4500-1 magnet (solenoid):

Housing: Plastic
Operating
temperature: - 40°C to + 60°C
BTL-P-1012-4R
BTL-P-1028-15R (special accessories for

applications with a supporting rod):
Housing: Anodized aluminum
120°
BTL-P-1014-2R
Ø 65
Ø 54
Ø 28
Ø 4.3 8
12.2 Mounting nut

BTL-P-0814-GR-PAF
–– M18×1.5 mounting nut:
BTL-A-FK01-E-M18×1.5
–– 3/4”-16UNF mounting nut:

BTL-A-FK01-E-3/4”-16UNF
Fig. 12-1: Magnet installation dimensions
12 Accessories (continued)
12.3 Connectors and cables BKS-S135M-00

Straight connector, freely configurable
M16 per IEC 130-9, 6-pin
BKS-S32M-00
Straight connector, freely configurable
~ 62
Fig. 12-6: Connector type BKS-S135M-00
~ 62
BKS-S136M-00
Angled connector, freely configurable
~ 54
Ø6-Ø8
BKS-S33M-00
Angled connector, freely configurable 31
~ 54
Ø6-Ø8
Ø 18
37.2
31
Ø 18
37.2
Ø 20
Ø 20
BKS-S115-PU-_ _
Straight connector, molded-on cable, preassembled
M12, 8-pin
Various cable lengths can be ordered, e.g.
BKS‑S115-PU-05: Cable length 5 m
43
Ø 13.5
M12x1
Fig. 12-4: Connector type BKS-S115-PU-_ _
BKS-S116-PU-_ _
Angled connector, molded-on cable, preassembled
M12, 8-pin
Various cable lengths can be ordered, e.g.
BKS‑S116-PU-05: Cable length 5 m
M12x1
28
Fig. 12-5: Connector type BKS-S116-PU_ _
24 english
Assembling instruction
Connector BKS-S32M-00
Usage Step 1 (see fig. 1) Carefully spread the slotted spacing

tube (7) and usher it over the leads.
The 8-pin connector of the series Thread the parts 1 to 5 on the cable
Place it on the socket body (8) and
BKS-S32M-00 is suitable for cables in the order shown.
line up the slot with the grove on
with a diameter of 6 to 8 mm. Cable end the socket body with the noses
(5) (4) (3) (2) (1) wedged so that the socket body
Technical Data and spacing tube do not turn against
each other.
S32 coupler socket (8) (7) (6) (5) (4)
System Binder series 423
Nominal voltage Fig. 1: Parts threaded on the cable
as per VDE 0110/72 Gr. A 60 V
Temperature range –40...+85 °C The PG screw must be screwed
Connection type soldered only later - in step 5!
Max. cross-section 0,75 mm2
Housing material CuZn, nickel Fig. 4: Leads soldered and
Step 2 (see fig. 2) spacing tube mounted
Socket body PBTP gv.
Contacts CuSn + 0,8 µm Au Bare and strip the cable braiding for
Protection class IP 67 a length of 20 mm. Step 4 (see fig. 5)
as per IEC 529 (in screwed state)
Cable inlet 6...8 mm Fan out the braid and lay it on the Slip the front housing (9) from the
Cable clamp PG 9 braid clamp (5), and cut out the over front with the inside thread towards
hanging braid. the cable end and make sure that
Strip the leads for about 4 mm, twist the wedge on the inside fits in the
Assembling and coat with a touch of solder. grove on the socket body (8) and
the slot on the spacing tube (7).
Take the 10 parts of the connector Thread the braid clamp (6) and Screw the front housing (9) on to the
out of the packing. clamp the braid against clamp (5). rear housing (4). While screwing
Braid laid on, make sure that the socket body
1 PG Screw over hanging braid cut out and the cable are not twisted (e.g.
by connecting the corresponding
2 Cable clamp plug of the BTL), in order to avoid
stress on the leads!
No. 810 314 DE • Edition 9708; Specifications subject to change without notice.
3 Rubber bush (9) (4)
4 Rear housing
(6) (5) (4) (3)
5 Braid clamp (coned inside)
Fig. 2: Braid clamped and
6 Braid clamp (coned outside) the leads stripped
7 Slotted spacing tube Step 3 (see fig. 3 and 4) Fig 5: Front housing mounted
8 Socket body Recommendation: Slip an 8 mm Step 5 (see fig. 6)

length of insulating sheath over
9 Front housing each lead. (Not included in deliv- Push the cable clamp (2) over the
with tube inside ery). rubber bush (3) and both of them
into rear housing (4). Screw in the
10 Flat (rubber) gasket Connect the leads to the socket PG screw (1) firmly into the rear
pins and solder (for pin assignment housing (torque as per
see the corresponding BTL operat- DIN VDE 0619).
ing manual). Push the insulating
sheaths over the soldered pins. Set the flat gasket (10) from the
front (line up nose and grove) and
carefully press it in all around.
View of pins:
soldering side
Gebhard Balluff GmbH & Co.

Fig. 3: Socket body (8)
Gartenstrasse 21-25 (10) (3) + (2) (1)
D-73765 Neuhausen/Germany
Phone (+49 71 58) 1 73-0 Fig 6: PG screw screwed,
Fax (+49 71 58) 50 10 connector assembled completely
2
1.3
P+I Diagrams
1/5
Client Parts List
Hydraulic Oil Supply Unit (HPSU) No. 1L 12728/A
Item Qty Definition / Type Manufacturer Drawing/KKS. No.

Material
10 1 Oil tank NG 450 asfa Stainless steel SS304
15 1 Oil tub NG 450 asfa Carbon steel
25 1 Oil drain valve KHB-G3/8 Hydac Viton seals
26 1 Oil drain valve KHB-G1 Hydac Viton seals
30 1 Oil level gauge FSA254-2.1/-/12 Hydac Viton seals
40 1 Air venting filter Hydac Viton seals

with water absorber
BLT M 160 F 3 W 1.X
50 1 Oil level transmitter Shridhan

FLX (output 4 to 20 mA, 2 wire)


55 1 Temperature transmitter Hydac 0-150°C / 4-20 mA

ETS3866-3-000-000 with TFP100
56 1 Temperature transmitter Hydac 0-150°C / 4-20 mA

ETS3866-3-000-000 with TFP100
65 1 Filter for Air/oil cooler Hydac Viton seals

RF BN/HC 160 D E 3 D 1.0/-V-L24
filtration rate: 3µ; size: 160
66 1 Filter for Air/oil cooler Hydac Viton seals

RF BN/HC 160 D E 3 D 1.0/-V-L24
67 1 Oil regeneration unit Rohm & Haas / Viton seals

Amberlyst/molecular sleeve Brenntag Eurochem
filtration rate: 3µ (absolute)
70 1 Internal gear pump Rexroth Viton seals

PGF2-2X/019 RA20 V P2
71 1 Internal gear pump Rexroth Viton seals

PGF2-2X/019 RA20 V P2
80 1 Coupling Hydac
2/5
Client Parts List

Material
81 1 Coupling Hydac
90 1 Pump yoke L-110 Lovejoy
91 1 Pump yoke L-110 Lovejoy
100 1 Electric motor, 11.0 kW ABB

415 V, V1, 1450 U/min.
101 1 Electric motor, 11.0 kW ABB

415 V, V1, 1450 U/min.
102 1 Gear pump unit Kracht/ABB Viton seals

KF16 RF2/332-D15-GJS with motor (1.1 kW)
103 1 Gear pump unit Kracht/ABB Viton seals

KF16 RF2/332-D15-GJS with motor (1.1 kW)
104 1 Air/oil cooler Hydac

OK-EL/4S/3.0/M/A/1
105 1 Air/oil cooler Hydac

OK-EL/4S/3.0/M/A/1
110 1 Check valve Hydac Viton seals

RVM10120-01-C-V-0.5

RVM10120-01-C-V-0.5

RVM10120-01-C-V-0.5

RVM10120-01-C-V-0.5
114 1 Check valve RV-20-01.X/H Hydac Viton seals
120 1 Pressure filter Hydac Viton seals

DF BN/HC 110 Q E 10 D 1.X/-V-L24
121 1 Pressure filter Hydac Viton seals

DF BN/HC 110 Q E 10 D 1.X/-V-L24
170 1 Pressure relief valve Rexroth Viton seals

DB10 K2-4X/200YV
3/5
Client Parts List

Material
171 1 Pressure relief valve Rexroth Viton seals

DB10 K2-4X/200YV
179 1 Diff. pressure switch Hydac

VR 2 D.0/-L24
180 1 Pressure transmitter ABB 0-600 bar / 4-20 mA

266 HSHVKBA1L1B6

266 HSHVKBA1L1B6

266 HSHVKBA1L1B6
183 1 Pressure switch Nautilius

XMLA 010 B 2 S 1 3

XMLA 010 B 2 S 1 3

XMLA 010 B 2 S 1 3
186 1 Pressure gauge WIKA

0-280 bar, ø100 mm, G1/2" BSP

0-10 bar, ø100 mm, G1/2" BSP

0-10 bar, ø100 mm, G1/2" BSP

0-10 bar, ø100 mm, G1/2" BSP
190 1 Shut off valve Hydac Viton seals

KHB-G1/2-1314-01X/H

KHB-G1/2-1314-01X/H

KHP-16-1314-02X/H

KHP-16-1314-02X/H
4/5
Client Parts List

Material

KHP-16-1314-02X/H

KHP-16-1314-02X/H

KHP-16-1314-02X/H
199 1 Shut off valve KHB-G1 Hydac Viton seals
200 1 Shut off valve DV-08-01.1/0 Hydac
320 1 2/2-way directional valve Hydac Single coil 24 V DC ± 5V

WS10Y-01-C-V-24DG Viton seals
321 1 2/2-way directional valve Hydac Single coil 24 V DC ± 5V

WS10Y-01-C-V-24DG Viton seals
700 1 Terminal box Hensel for signals

Mi 0200 Electric India
703 1 Terminal box Hensel for motor power

810 1 Bladder accumulator NG 32 Hydac Viton bladder

SB330-32A1/116-330A
811 1 Bladder accumulator NG 32 Hydac Viton bladder

SB330-32A1/116-330A
820 1 Safety and shut-off block Hydac Viton seals

SAF20M16T210A-S13
821 1 Safety and shut-off block Hydac Viton seals

SAF20M16T210A-S13

in SAF20M16T210A-S13

840 1 Pressure relief valve Hydac Viton seals

5/5
Client Parts List

Material
841 1 Pressure relief valve Hydac Viton seals

850 1 Drain valve Hydac Viton seals

851 1 Drain valve Hydac Viton seals


0-280 bar, ø100 mm, G1/2" BSP

0-280 bar, ø100 mm, G1/2" BSP
P1 1 Flexible hoses 4SP - DN 20

length: 1500 mm; connection: SAE flange
P2 1 Flexible hoses 4SP - DN 20

T1 1 Flexible hoses 4SN - DN 25

T2 1 Flexible hoses 4SN - DN 25

1/2
Client Parts List
Hydraulic Control Unit for LP Bypass Stop Valve No. 2L 12729/A

Material
320 1 Filter (manifold mounting type) Hydac Viton seals

DF BN/HC 140 Q E 10 D 1.X/-V-L24
350 1 3/2-way solenoid valve Rexroth Single coil 25 V DC ± 5V

M-3SED10CK1X/350CG24N9K4 Viton seals
351 1 3/2-way solenoid valve Hydac Single coil 25 V DC ± 5V

WSM08130C-01-C-V-24DG Viton seals

WSM08130C-01-C-V-24DG Viton seals
360 1 Flow control valve Hydac Viton seals

DVE-16-01.X/V/H

DVE-08-01.X/V/H

DVE-08-01.X/V/H

SDR10A-01-C-V-15 V
451 1 Cartridge cover Hydac/Rexroth Viton seals

LD-CCE 16 D 6 1D
452 1 Cartridge valve Hydac/Rexroth Viton seals

L-CEE 16 B 6 B X
453 1 Cartridge cover Hydac/Rexroth Viton seals

LD-CCE 16 D 6 1D
454 1 Cartridge valve Hydac/Rexroth Viton seals

L-CEE 16 B 6 B X
500 1 Hydraulic actuator asfa Viton seals

CER 250 C 125/56x125 DV
501 1 Limit switch GLAA01A1B Honeywell
505 1 Leackage sensor KI5038 IFM

2/2
Client Parts List
Hydraulic Control Unit for LP Bypass Stop Valve No. 2L 12729/A

Material
701 1 Junction box Hensel

P 1 Flexible hoses 4SP - DN 20

T 1 Flexible hoses 4SN - DN 25

1/1
Client Parts List
Hydraulic Control Unit for LP Bypass Control Valve No. 2L 12730/A

Material
310 1 Servo valve Rexroth Control oil supply external

4WS2EM10-5X/45B11ET315K31EV Viton seals

DF BN/HC 60 Q E 10 D 1.X/-V-L24

DF BN/HC 30 Q E 10 D 1.X/-V-L24

WSM08130D-01-C-V-24DG Viton seals

DVE-08-01.X/V/H
371 1 Pilot operated check valve Hydac Viton seals

ERVE-R1-10X
372 1 Pilot operated check valve Hydac Viton seals

ERVE-R1-10X
510 1 Hydraulic actuator asfa Viton seals

CER 250 C 80/36x155 DVUW
581 1 Ultrasonic position transmitter Balluff

BTL7-E170-M0200-B-S32
702 1 Junction box Hensel

P 1 Flexible hoses 4SP - DN 20

T 1 Flexible hoses 4SN - DN 25

1.4
(HPSU) 450 ltr.
405
200 300
299
2055
400
1632 4x 17 thru
250 1900
2400
2432
Rear view
External piping
280 160 150 1000
4x 17 thru
T2 T1 P2 P1
2000
1600
1550
25
20 2360
2400
Mounting Bolt
1:2
References:
M16 The required space for maintenance and repair work
around the HPSU is 1000 mm in all 4 directions.
In addtion the roof of the HPSU cabinet has to be
23
disassembled to take out the electric motors or the

accumulators.
That means there has be access for a lifting device
122
140
above the HPSU roof of approx 2500 mm A Connection A, B, C, D changed to P1, P2, T1, T2 13.08.2013 Propp/Cordr.
Weight of the HPSU (With oil filling): approx 2800 kg. Rev
Komm. Nr. -
ÄNDERUNGSTEXT
AKZ Nr. -
REVISION DATUM
Artikel Nr.
REVISION NAME
Werkstoff: Ers. f.: - Ers. d.: -

Gewicht: - kg
QS-Überprüfung nach DIN ISO 9001
Maßstab: 1:8
Datum Name Benennung:
An dieser Zeichnung behalten wir
Bearb.
Hydraulikstation 450L
uns die gesetzlichen Urheber- 30.04.2013 Propp
16 schutzrechte vor. Ohne unsere
vorherige Zustimmung darf diese
Gepr. 30.04.2013 Cordruwisch
Zeichnung weder vervielfältigt Hydraulic power supply unit (HPSU)
noch Dritten zugänglich gemacht CAD:
werden. Sie darf auch nicht Blatt
Zeichng.Nr.:
durch den Empfänger oder Dritte 1
0L 12318 / A
Maße ohne Toleranzangabe
in anderer Weise mißbräuchlich nach
Zeichnung darf nur im CAD geändert werden! verwendet werden. DIN 7168 mittel 1 Bl.
Y:\SolidWorks\asfa\08_Hydac Indien\02-PP01201-a-GA_450L\Hydraulic power supply unit (HPSU) 0L 12318
1.5
Hydraulic Control Units with
actuator
LP Bypass Stop Valve
type:
CER 250 C 125/56 x 125 DV
196 T (connction)
604
489,5
332
175
P (connction)
400 330 200
Rev. Änderung Datum Name

Komm. Nr. - AKZ Nr. - Artikel Nr. -

Gewicht: 232.47 kg
Maßstab: 1:5
Datum Name
uns die gesetzlichen Urheber- Bearb. 29.04.2013 Propp
Benennung:
Dimension drawing
schutzrechte vor. Ohne unsere Gepr. 29.04.2013 Cordruwisch Hydraulic Actuator with control block
Zeichnung weder vervielfältigt
Type: CER250C125/56x125(155)DV
Zeichng.Nr.:
2L 12050H1
in anderer Weise mißbräuchlich nach
Zeichnung darf nur im CAD geändert werden! verwendet werden. DIN 7168 mittel 1 Bl.
Y:\SolidWorks\MaxxDBDaten\D_000\DIF.-ZYL._CER250C125_56x125(155)DV_mit_Steuerblock_Hydac-908.247-9_mit_Steuerblock_Hydac~0
M20
22,5° 67
,5°
A B
345
Hub=120
M45x1,5
205
360
125
56
0
32
35
A B
5
45 A-A
482
45 45
30 30
15 15
M10
20/22 tief
M10
20/22 tief
20
20
50
50
25
25
5 5
1
315
B-B
D Maß hinzugefügt 06.08.2012 Propp
Rev ÄNDERUNGSTEXT REVISION DATUM REVISION NAME

Gewicht: 113.9 kg
Maßstab: 1:2
Datum Name
Benennung:
Hydraulic actuator
schutzrechte vor. Ohne unsere Gepr. 13.06.2012 Cordruwisch connection drawing
Zeichnung weder vervielfältigt CER250C125/56x125DV
Zeichng.Nr.:
durch den Empfänger oder Dritte Maße ohne Toleranzangabe 1
Zeichnung darf nur im CAD geändert werden! in anderer Weise mißbräuchlich
verwendet werden.
nach
DIN 7168 mittel
1L 12050/D 1 Bl.
Y:\SolidWorks\asfa\H-10192-HA\Pos.01\Hydraulikzylinder - 1L 12050 D
1/1
Client Parts List (LP Bypass Stop Valve)
Hydraulic Actuator CER250C125/56x125DV Drawing-No. 1L 12050/D
Article Item Qty Definition Drawing/Ref. no.
908.264 10 1 Cylinder tube 2L 11816

1.0570
908.265 20 1 Cylinder head 0L 11817

1.0570
908.266 30 1 Cylinder bottom 2L 11818

1.0570
900.797 50 8 Fillister screw 10.9
908.142 70 2 O-ring (material: Viton)
900.956 80 1 Restrictor screw 4L 10124

10.9
901.471 90 1 Screw plug 3/8”
903.333 100 1 Measuring connection w/ plug coupler
908.747 110 1 Piston rod 2L 11190

1.0503
900.987 120 1 Piston 4L 10126

1.0570
900.959 130 1 Damping sleeve 4L 10125

1.7225
900.960 140 1 Adjusting nut 4L 10090

1.0570
000452 190 1 Threaded pin
908.143 200 1 Double scraper (material: Viton)
908.144 210 2 Piston rod seal (material: Viton)
901.442 220 2 Rod guide strip
908.145 230 1 Piston seal (material: Viton)
901.621 240 2 Piston guide ring
901.059 300 1 Collar nut

1/1
Client Spare Parts List (LP Bypass Stop Valve)
Hydraulic Actuator CER250C125/56x125DV Drawing-No. 1L 12050/D

LP Bypass Control Valve
type:
CD 250 C 80/36 x 155 DBUW
223
108
121 152
P(connection)
594
T (connection)
286
829

Gewicht: 135.47 kg
Maßstab: 1:5
Datum Name
Benennung:
Dimension drawing
schutzrechte vor. Ohne unsere Gepr. 30.04.2013 Cordruwisch Hydraulic Actuator with control block
Zeichnung weder vervielfältigt Type: CD250C80/36x155(195) DBUW
Zeichng.Nr.:
3L 12051H1
verwendet werden.
nach
DIN 7168 mittel 1 Bl.
Y:\SolidWorks\MaxxDBDaten\D_000\DIF.-ZYL._CD250C80_36x155(169)DBUW_mit_Steuerblock_Hydac-908.746-5_mit_Steuerblock_Hydac~0
599
Leckage
Leakage
110 200 20 210 220 70 130 160 120 10 230 240 140 190 150 310 180 70 30 270 250 290 280 320
A B
Hub=150
36
Stroke=150
80
M30x1,5
200
130
36
45
235
A Dämpfung (DB)
Dämpfung (DB)
Damping (DB) B 300
300 80 Damping (DB) 80
100
25
5
355
325
20
20
50
50
25
25
M8 M8
20 20/22 tief 20/22 tief 20
35 35
50 50
M12 22,5°
60
100 50
8x
45
°
E Drosselschraube geändert 08.04.2013 Propp
D Maß hinzugefügt 06.08.2012 Propp
C Erweiterte Ansicht 13.06.2012 Propp
Rev ÄNDERUNGSTEXT REVISION DATUM REVISION NAME

Rev. Änderung Datum Name
Komm. Nr. - AKZ Nr. - Artikel Nr. 908.746

0
10
Gewicht: 47.35 kg
0 QS-Überprüfung nach DIN ISO 9001
18 Maßstab: 1:1
Datum Name
uns die gesetzlichen Urheber- Bearb. 21.01.2011 Liu
Benennung:
Hydraulic actuator
schutzrechte vor. Ohne unsere Gepr. 24.01.2011 Meng connection drawing
vorherige Zustimmung darf diese Freig. 09.02.2011 Cordruwisch
Zeichnung weder vervielfältigt CD250C80/36x155 DBUW
A-A (1 : 2) B-B (1 : 2) C (1:2) noch Dritten zugänglich gemacht
werden. Sie darf auch nicht
durch den Empfänger oder Dritte
CAD:
Maße ohne Toleranzangabe Zeichng.Nr.: Blatt

1
verwendet werden.
nach
DIN 7168 mittel
1L 12051 / E 1 Bl.
Y:\SolidWorks\MaxxDBDaten\D_000\DIF.-ZYL._CD250C80_36x155(195)DBUW~-e
1/2
Client Parts List (LP Bypass Control Valve)
Hydraulic Actuator CD250C80/36x155DBUW Drawing-No. 1L 12051/E
908.748 10 1 Cylinder tube 2L 12052

1.0570
908.269 20 1 Cylinder head 1L 11821

1.0570
908.270 30 1 Cylinder bottom 2L 11822

1.0570
909.318 80 2 Restrictor screw 4L 12316

10.9
903.333 100 2 Measuring connection w/ plug coupler
908.749 110 1 Piston rod 3L 10247

1.0503
901.617 120 1 Piston 4L 10248/a

1.0570
900.998 130 1 Damping sleeve 4L 10121/a

1.7225
901.017 140 1 Damping sleeve 4L 10132/a

1.7225
908.347 150 1 Ring 4L 11852

1.4571
908.348 180 2 Fillister screw MS
000452 190 1 Threaded pin

2/2
Client Parts List (LP Bypass Control Valve)
906.671 250 1 Protective hood 4L 11225

1.0037
000523 270 4 Fillister screw 8.8
908.767 280 1 Ultrasonic position transmitter BTL7 (Balluff)
901.931 290 1 Seal
906.448 300 1 Collar nut
900.305 310 1 Magnet for position transmitter
903.061 320 1 Connector for position transmitter

1/1
Client Spare Parts List (LP Bypass Control Valve)
908.767 280 1 Ultrasonic position transmitter BTL7 (Balluff)
901.931 290 1 Seal

1.6
Electrical documentation
(wiring drawing)
0 1 2 3 4 5 6 7 8 9
Asfa Antriebssysteme
Company / customer Bharat Heavy Electricals Limited (India)

Project description HPSU and Actuators Bhadradri (4x270 MW)
Job number
Commission 1400630 / 1400655
Project name PP01201
Created on 14/12/2015
Edit date 14/12/2015 by (short name) RITESHC Number of pages 28
2
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme =
Ed. RITESHC +
Rev a 07-05-2013 RITESH Appr HPSU and Actuators Bhadradri (2x270 MW) Page 1
Modification Date Name Original Replaced by Replaced by Page 28
0 1 2 3 4 5 6 7 8 9
Table of contents Column X: An automatically generated page was edited F06_001
Page Page description supplementary page field Date Edited by X

=+/1 5/7/2013 RITESHC X
=+/2 5/7/2013 RITESHC X
=+/3 Motor Emergency Push Button Station 5/7/2013 RITESHC
=+/4 Motor Terminal Box Dimension HPSU ITEM 703 5/7/2013 RITESHC
=+/5 Instruments Junction Box Dimension HPSU ITEM 700 5/7/2013 RITESHC
=+/6 HV10030 Junction Box Dimension 701 STOP VALVE 5/7/2013 RITESHC
=+/7 HV10031 Junction Box Dimension 702 CONTROL VALVE 5/7/2013 RITESHC
=+/8 Table of contents : =+/1 - =+/21
=+/9 PP01201 Motor Teminal Box Wiring {Control} HPSU ITEM 703 5/7/2013 RITESHC
=+/10 PP01201 Motor Terminal Box {Power} HPSU ITEM 703 5/7/2013 RITESHC
=+/11 PP01201 Motor Terminal Box {Power} HPSU ITEM 703 5/7/2013 RITESHC
=+/12 PP01201 Instruments Junction Box HPSU ITEM 700 5/7/2013 RITESHC
=+/18 HV10030 JUNCTION BOX 701 STOP VALVE 5/7/2013 RITESHC
=+/19 HV10030 JUNCTION BOX 701 STOP VALVE 5/7/2013 RITESHC
=+/20 HV10031 JUNCTION BOX 702 CONTROL VALVE 5/7/2013 RITESHC
=+/21 HV10031 JUNCTION BOX 702 CONTROL VALVE 5/7/2013 RITESHC
1 3
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme Table of contents : =+/1 - =+/21 =
Ed. RITESHC +
Modification Date Name Original Replacement of Replaced by Page 28
0 1 2 3 4 5 6 7 8 9
PP01201 MOTOR EMERGENCY PUSH BUTTON STATION
200 98
Emergency
Stop
160
HENSEL K8250
2 4
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme Motor Emergency Push Button =
Ed. RITESHC
Station +
0 1 2 3 4 5 6 7 8 9
Motor Terminal Box

HPSU Item 703
450 170
Supplier Wiring Duct
300 300
Customer Wiring Duct
HENSEL Mi 0300
3 5
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme Motor Terminal Box Dimension =
Ed. RITESHC
HPSU ITEM 703 +
0 1 2 3 4 5 6 7 8 9
Instruments Terminal Box

HPSU Item 700
300 170
300
(C) HENSEL
AWT 01.97
HENSEL Mi 0200
4 6
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme Instruments Junction Box =
Ed. RITESHC
Dimension HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9
HV10030 Terminal Box 701
150 mm 170 mm
300 mm
(C) HENSEL
AWT 01.97
HENSEL Mi 0100
5 7
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme HV10030 Junction Box Dimension =
Ed. RITESHC
701 STOP VALVE +
0 1 2 3 4 5 6 7 8 9
HV10031 Terminal Box 702
150 mm 170 mm
300 mm
(C) HENSEL
AWT 01.97
HENSEL Mi 0100
6 9
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme HV10031 Junction Box Dimension =
Ed. RITESHC
702 CONTROL VALVE +
0 1 2 3 4 5 6 7 8 9
MOTOR TERMINAL BOX

HPSU Item 703
-X1 1 2
PE
-W1
2x2.5
1100 V RD BL
11
-S1
12
7 10
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme PP01201 Motor Teminal Box Wiring =
Ed. RITESHC
{Control} HPSU ITEM 703 +
0 1 2 3 4 5 6 7 8 9
MOTOR TERMINAL BOX

HPSU Item 703
-X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-W6 -W7 -W8 -W9

POLYCAB POLYCAB POLYCAB POLYCAB
4x6 4x6 4x2.5 4x2.5
1100 RD YE BN GN 1100 RD YE BN GN 1100 RD YE BN GN 1100 RD YE BN GN
U1 V1 W1 U1 V1 W1 U1 V1 W1 U1 V1 W1
-M13.1
M -M13.2
M -M34.1
M -M34.2
M
11 KW, 415 V AC, 50 Hz 3~ 11 KW, 415 V AC, 50 Hz 3~ 1.1 KW, 415 V AC, 50 Hz 3~ 1.1 KW, 415 V AC, 50 Hz 3~
3 PH PE 3 PH PE 3 PH PE 3 PH PE
1455 RPM 1455 RPM 1420 RPM 1420 RPM
HIPL TP No. 13 HIPL TP No. 13 HIPL TP No. 34 HIPL TP No. 34
Item 100 Item 101 Item 102 Item 103

MAX 05 AP 001 MAX 05 AP 002 MAX 05 AP 011 MAX 05 AP 012
9 11
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme PP01201 Motor Terminal Box =
Ed. RITESHC
{Power} HPSU ITEM 703 +
0 1 2 3 4 5 6 7 8 9
MOTOR TERMINAL BOX

HPSU Item 703
-X2 17 18 19 20 21 22 23 24
-W39 -W40
POLYCAB POLYCAB
4x2.5 4x2.5
1100 RD YE BN GN 1100 RD YE BN GN
U1 V1 W1 U1 V1 W1
-M35
M -M36
M
0.37 KW, 415 V AC, 50 Hz 3~ 0.37 KW, 415 V AC, 50 Hz 3~
3 PH PE 3 PH PE
1455 RPM 1455 RPM
HIPL TP No. 41.1 HIPL TP No. 41.2
Item 104 Item 105

MAX 05 AN 011 MAX 05 AN 012
10 12
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme PP01201 Motor Terminal Box =
Ed. RITESHC
{Power} HPSU ITEM 703 +
0 1 2 3 4 5 6 7 8 9
INSTRUMENTS TERMINAL BOX HPSU Item 700

Electronic Temprature Switch & Level Transmitter
-X3 56 57 58 59 60 61 62 63 64 -X3 1 2 3 4 5 6 7 8
-W36 -W37 -W38

2x0.34 2x0.34 2x0.34 -W10 -W11
250 BR WH GR 250 BR WH GR 250 BR WH GR LICYC LICYC
4x0.25 BR GN WH YE 4x0.25 BR GN WH YE
+vE -vE +vE -vE +vE -vE 1 2 3 4 1 2 3 4

Supply +Ve 0V 4-20 mA SP 1 Supply +Ve 0V 4-20 mA SP 1
L L L T T
-LT5.1 -LT5.2 -LT5.3
HIPL TP No. 7 HIPL TP No. 7
Level Transmitter Level Transmitter Level Transmitter
Electronic Temperature Switch Electronic Temperature Switch
HIPL TP No. 5.1 HIPL TP No. 5.2 HIPL TP No. 5.2
-ETS7.1 -ETS7.2
Item 50 Item 51 Item 52

Item 55 Item 56
MAX 05 CL 001 MAX 05 CL 002 MAX 05 CL 003
MAX 05 CT 001 MAX 05 CT 002
11 13
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme PP01201 Instruments Junction Box =
Ed. RITESHC
HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9

HART Pressure Transmitter
-X3 9 10 11 12 13 14 15 16 17
-W12 -W13 -W14

2x2x0,34 2x2x0,34 2x2x0,34
250 V BR WH GR 250 V BR WH GR 250 V BR WH GR
+vE -VE +vE -VE +vE -VE
P P P
PT21.1 -PT21.2 -PT21.3
Pressure Transmitter Pressure Transmitter Pressure Transmitter
HIPL TP No. 21 HIPL TP No. 21 HIPL TP No. 21

MAX 05 CP 001 MAX 05 CP 002 MAX 05 CP 003
12 14
Ed. RITESHC
HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9

Pressure Switch
-X3 18 21 19 20 22 25 23 24 26 29 27 28
-W15 -W16 -W17

4x0.5 BR GN WH YE 4x0.5 BR GN WH YE 4x0.5 BR GN WH YE
C C C
1 PE 1 PE 1 PE
P P P
2 3 2 3 2 3
NC NO NC NO NC NO
PS21.1 PS21.2 PS21.3

Pressure Switch Pressure Switch Pressure Switch
Nautilius Nautilius Nautilius

MAX 05 CP 020 MAX 05 CP 021 MAX 05 CP 026
13 15
Ed. RITESHC
HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9

Pressure Line Filter Clogging Indication
-X3 30 31 32 33 34 35 36 37
Item 120 Item 121

MAX 05 CP 011 MAX 05 CP 012
-W18 -W19
4x0.5 WH BR YE GN 4x0.5 WH BR YE GN
CL18.1 CL18.2
Clogging Indicator Clogging Indicator
0V PE 0V PE
P P
C NC C NC
14 16
Ed. RITESHC
HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9

Return Line Filter Clogging Indication
-X3 38 39 40 41 42 43 44 45 46 47 48 49

-W20 MAX 05 CP 013 -W21 MAX 05 CP 014 -W22 MAX 05 CP 027
4x0.5 WH BR YE GN 4x0.5 WH BR YE GN 4x0.5 WH BR YE GN
CL54.1 CL54.2 CL55

Clogging Indicator Clogging Indicator Clogging Indicator
0V PE 0V PE 0V PE
P P P
C NC C NC C NC
15 17
Ed. RITESHC
HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9
INSTRUMENTS TERMINAL BOX

AT DISCHARGE OF OIL PUMPS (HPSU)
Solenoid Valves
-X3 50 51 52 53 54 55
-W23 -W24
4x0.75 BR WH GN 3x0.75 BR WH GN
SV15.1 1 2 PE SV15.2 1 2 PE
SV15.1 SV15.2
Item 320 Item 321
MAX 05 AA 011 MAX 05 AA 012
16 18
Ed. RITESHC
HPSU ITEM 700 +
0 1 2 3 4 5 6 7 8 9
HV10030 TERMINAL BOX 701

Solenoid Valves
-X4 1 2 3 4 5 6 7 8 9 29 30 31 32
-W25 -W26 -W29

4x0.75 BR WH GN 4x0.75 BR WH GN 4x0.75 BR WH GN
-CL320
SV3 1 2 3 SV5.1 1 2 3 SV5.2 1 2 3 Clogging Indicator
0V PE
HIPL TP No. 3 HIPL TP No. 5.1 HIPL TP No. 5.2 P

SV3 -SV5.1 -SV5.2
C NC
Item 320
MAN41/51CP021
MAN 41/51 AA011 MAN 41/51 AA013 MAN 41/51 AA014
17 19
Date 5/8/2013 1400630/1400655 Asfa Antriebssysteme HV10030 JUNCTION BOX 701 STOP =
Ed. RITESHC
VALVE +
0 1 2 3 4 5 6 7 8 9

Limit Switch and Oil Leakage Sensor
-X4 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
-501 -502 -503 -504 -K1-3015
NO C NC C -NO -C -NC -C -NO -C -NC -C -NO -C -NC -C L+:1 4 L-:3

13 11 13 11 13 11 13 11
14 12 14 12 14 12 14 12
Item 501 Item 502 Item 503 Item 504

MAN 41/51 CG001B MAN 41/51 CG001D MAN 41/51 CG001C MAN 41/51 CG001E MAN 41/51 CL011
18 20
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme HV10030 JUNCTION BOX 701 STOP =
Ed. RITESHC
VALVE +
0 1 2 3 4 5 6 7 8 9

Solenoid Valve, Servo valve and Position Transmitter
-X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
-W27
4x0.75 BR WH GN
SV4 1 2 3
-310 -581 YE GY PK RD GN BU BN WH
A B C D E F 1 2 3 4 5 6 7 8
HIPL TP No. 4
Lb {Programming
La {Programming
Valve Coil A +Ve
Valve Coil B +Ve
Output Value
Valve Coil A -Ve
Valve Coil B -Ve
Input}
Input}
24 V DC
Output
20 - 4 mA
GND
0V
SV4

MAN 42/52 AA011 MAN 42/52 AA012 MAN 42/52 CG001A
19 21
Date 5/8/2013 1400630/1400655 Asfa Antriebssysteme HV10031 JUNCTION BOX 702 =
Ed. RITESHC
CONTROL VALVE +
0 1 2 3 4 5 6 7 8 9

Clogging Indicator - Pressure Line Filter
-X5 18 19 20 21 22 23 24 25
-CL321 -CL322
Clogging Indicator Clogging Indicator
0V PE 0V PE
P P
C NC C NC
Item 321 Item 322

MAN 42/52CP021 MAN 42/52CP022
20 22
Date 5/8/2013 1400630/1400655 Asfa Antriebssysteme HV10031 JUNCTION BOX 702 =
Ed. RITESHC
CONTROL VALVE +
0 1 2 3 4 5 6 7 8 9
Cable overview F10_001
Conductors Cross-section Graphical page

Cable name Source (from) Target (to) cable type all conductors Length [m] function text
used [mm] of cable diagram
-W1 -X1 -S1 POLYCAB 2 2 2.5 PVC INSULATED, INNER SHEATHED
-W6 -X2 -M13.1 POLYCAB 4 4 6 =
-W7 -X2 -M13.2 POLYCAB 4 4 6 =
-W8 -X2 -M34.1 POLYCAB 4 4 2.5 PVC SHEATHED
-W9 -X2 -M34.2 POLYCAB 4 4 2.5 =
-W10 -X3 -ETS7.1 LICYC 4 4 0.25
-W11 -X3 -ETS7.2 LICYC 4 4 0.25
-W12 -X3 -PT21.1 ELECTRONIC-LIY(C)-PUR 2x2 2 0,34
-W15 -X3 -PS21.1 LAPP OLFLEX 110 4 4 0.5
-W16 -X3 -PS21.2 LAPP OLFLEX 110 4 4 0.5
-W17 -X3 -PS21.3 LAPP OLFLEX 110 4 4 0.5
-W18 -X3 -CL18.1 LAPP OLFLEX 110 4 4 0.5
-W19 -X3 -CL18.2 LAPP OLFLEX 110 4 4 0.5
-W20 -X3 -CL54.1 LAPP OLFLEX 110 4 4 0.5
-W21 -X3 -CL54.2 LAPP OLFLEX 110 4 4 0.5
-W22 -X3 -CL55 LAPP OLFLEX 110 4 4 0.5
-W23 -SV15.1 -X3 LAPP OLFLEX 110 4 4 0.75
-W24 -SV15.2 -X3 LAPP OLFLEX 110 3 2 0.75

-W25 -SV3 -X4 LAPP OLFLEX 110 4 3 0.75
-W26 -SV5.1 -X4 LAPP OLFLEX 110 4 3 0.75
-W27 -SV4 -X5 LAPP OLFLEX 110 4 3 0.75
-W29 -SV5.2 -X4 LAPP OLFLEX 110 4 3 0.75
-W36 -X3 -LT5.1 ELECTRONIC-LIY(C)-PUR 2 2 0.34
-W39 -X2 -M35 POLYCAB 4 4 2.5 PVC INSULATED, INNER SHEATHED
-W40 -X2 -M36 POLYCAB 4 4 2.5 =
21 23
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme Cable overview : =+-W1 - =+-W40 =
Ed. RITESHC +
0 1 2 3 4 5 6 7 8 9
Terminal diagram F13_001
-W1
Strip
Cable name
Cable name
=+-X1
POLYCAB
Connection
Connection
cable type
cable type
terminal
jumper
point
point
function text Target designation Target designation Page / column
RD -S1 11 1 /9.4
BL -S1 12 2 /9.5
22 24
Date 5/7/2013 1400630/1400655 Asfa Antriebssysteme Terminal diagram =+-X1 =
Ed. RITESHC +
0 1 2 3 4 5 6 7 8 9
-W40
-W39
-W9
-W8
-W7
-W6
Strip
Cable name
Cable name
=+-X2
POLYCAB
POLYCAB
POLYCAB
POLYCAB
POLYCAB
POLYCAB
Connection
Connection
cable type
cable type
terminal
jumper
point
point
RD -M13.1 U1 1 /10.1
YE -M13.1 V1 2 /10.1
BN -M13.1 W1 3 /10.1
GN -M13.1 PE 4 /10.2
RD -M13.2 U1 5 /10.3
YE -M13.2 V1 6 /10.3
BN -M13.2 W1 7 /10.4
GN -M13.2 PE 8 /10.4
RD -M34.1 U1 9 /10.6
YE -M34.1 V1 10 /10.6
BN -M34.1 W1 11 /10.6
GN -M34.1 PE 12 /10.7
RD -M34.2 U1 13 /10.8
YE -M34.2 V1 14 /10.8
BN -M34.2 W1 15 /10.9
GN -M34.2 PE 16 /10.9
RD -M35 U1 17 /11.1
YE -M35 V1 18 /11.1
BN -M35 W1 19 /11.1
GN -M35 PE 20 /11.2
RD -M36 U1 21 /11.3
YE -M36 V1 22 /11.3
BN -M36 W1 23 /11.4
GN -M36 PE 24 /11.4
23 25
Ed. RITESHC +
0 1 2 3 4 5 6 7 8 9
-W17
-W16
-W15
-W14
-W13
-W12
-W11
-W10
Strip
Cable name
Cable name
=+-X3
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
ELECTRONIC-LIY(C)-PUR
LICYC
LICYC
Connection
Connection
cable type
cable type
terminal
jumper
point
point
BR -ETS7.1 1 1 /12.5
GN -ETS7.1 2 2 /12.6
WH -ETS7.1 3 3 /12.6
YE -ETS7.1 4 4 /12.6
BR -ETS7.2 1 5 /12.7
GN -ETS7.2 2 6 /12.8
WH -ETS7.2 3 7 /12.8
YE -ETS7.2 4 8 /12.9
BR -PT21.1 +vE 9 /13.2
WH -PT21.1 -VE 10 /13.3
GR 11 /13.3
BR -PT21.2 +vE 12 /13.4
WH -PT21.2 -VE 13 /13.5
GR 14 /13.6
BR -PT21.3 +vE 15 /13.7
WH -PT21.3 -VE 16 /13.8
GR 17 /13.8
BR -PS21.1 1 18 /14.1
WH -PS21.1 3 19 /14.2
YE -PS21.1 2 20 /14.3
GN -PS21.1 PE 21 /14.2
BR -PS21.2 1 22 /14.4
WH -PS21.2 3 23 /14.5
YE -PS21.2 2 24 /14.6
GN -PS21.2 PE 25 /14.5
BR -PS21.3 1 26 /14.7
WH -PS21.3 3 27 /14.8
YE -PS21.3 2 28 /14.8
GN -PS21.3 PE 29 /14.8
24 25.a
Ed. RITESHC +
0 1 2 3 4 5 6 7 8 9
-W36
-W24
-W23
-W22
-W21
-W20
-W19
-W18
Strip
Cable name
Cable name
=+-X3
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
Connection
Connection
cable type
cable type
terminal
jumper
point
point
WH -CL18.1 2 30 /15.1
BR -CL18.1 1 31 /15.1
YE -CL18.1 32 /15.3
GN -CL18.1 33 /15.3
WH -CL18.2 2 34 /15.4
BR -CL18.2 1 35 /15.5
YE -CL18.2 36 /15.6
GN -CL18.2 37 /15.7
WH -CL54.1 2 38 /16.0
BR -CL54.1 1 39 /16.0
YE -CL54.1 40 /16.2
GN -CL54.1 41 /16.3
WH -CL54.2 2 42 /16.4
BR -CL54.2 1 43 /16.4
YE -CL54.2 44 /16.6
GN -CL54.2 45 /16.6
WH -CL55 2 46 /16.7
BR -CL55 1 47 /16.7
YE -CL55 48 /16.9
GN -CL55 49 /16.9
BR -SV15.1 1 50 /17.2
WH -SV15.1 2 51 /17.3
GN -SV15.1 PE 52 /17.4
BR -SV15.2 1 53 /17.7
WH -SV15.2 2 54 /17.8
GN -SV15.2 PE 55 /17.8
BR -LT5.1 +vE 56 /12.0
WH -LT5.1 -vE 57 /12.1
GR 58 /12.1
25 25.b
Ed. RITESHC +
Rev a 07-05-2013 RITESH Appr HPSU and Actuators Bhadradri (2x270 MW) Page 25.a
0 1 2 3 4 5 6 7 8 9
-W38
-W37
Strip
Cable name
Cable name
=+-X3
Connection
Connection
cable type
cable type
terminal
jumper
point
point
BR -LT5.2 +vE 59 /12.2

WH -LT5.2 -vE 60 /12.2
GR 61 /12.3
BR -LT5.3 +vE 62 /12.3
WH -LT5.3 -vE 63 /12.4
GR 64 /12.4
25.a 26
Ed. RITESHC +
Rev a 07-05-2013 RITESH Appr HPSU and Actuators Bhadradri (2x270 MW) Page 25.b
0 1 2 3 4 5 6 7 8 9
-W29
-W26
-W25
Strip
Cable name
Cable name
=+-X4
LAPP OLFLEX 110
LAPP OLFLEX 110
LAPP OLFLEX 110
Connection
Connection
cable type
cable type
terminal
jumper
point
point
BR -SV3 1 1 /18.0
WH -SV3 2 2 /18.1
GN -SV3 3 3 /18.1
BR -SV5.1 1 4 /18.2
WH -SV5.1 2 5 /18.3
GN -SV5.1 3 6 /18.3
BR -SV5.2 1 7 /18.4
WH -SV5.2 2 8 /18.5
GN -SV5.2 3 9 /18.5
-501-NO 10 /19.0
-501-C 11 /19.0
-501-NC 12 /19.1
-501-C 13 /19.1
-502-NO 14 /19.2
-502-C 15 /19.2
-502-NC 16 /19.3
-502-C 17 /19.3
-503-NO 18 /19.4
-503-C 19 /19.4
-503-NC 20 /19.5
-503-C 21 /19.5
-504-NO 22 /19.6
-504-C 23 /19.6
-504-NC 24 /19.7
-504-C 25 /19.7
-K1-3015-L+ 1 26 /19.8
-K1-3015-L+ 4 27 /19.8
-K1-3015-L- 3 28 /19.9
-CL320 2 29 /18.6
-CL320 1 30 /18.7
-CL320 31 /18.8
-CL320 32 /18.8
33
25.b 27
Ed. RITESHC +
0 1 2 3 4 5 6 7 8 9
-W27
Strip
Cable name
Cable name
=+-X5
LAPP OLFLEX 110
Connection
Connection
cable type
cable type
terminal
jumper
point
point
BR -SV4 1 1 /20.1
WH -SV4 2 2 /20.2
GN -SV4 3 3 /20.2
-310 A 4 /20.3
-310 B 5 /20.3
-310 C 6 /20.4
-310 D 7 /20.4
-310 E 8 /20.4
-310 F 9 /20.5
-581 1 10 /20.5
-581 2 11 /20.6
-581 3 12 /20.6
-581 4 13 /20.7
-581 5 14 /20.7
-581 6 15 /20.8
-581 7 16 /20.8
-581 8 17 /20.9
-CL321 2 18 /21.0
-CL321 1 19 /21.1
-CL321 20 /21.2
-CL321 21 /21.2
-CL322 2 22 /21.3
-CL322 1 23 /21.3
-CL322 24 /21.5
-CL322 25 /21.5
26
Ed. RITESHC +
Consumer lists
Power station ident. system no. (TAG-No.) Item 100
Designation Three-phase motor for main oil pump
Nominal voltage 3 x 415 V 10% / 50 Hz
Nominal power 11.0 kW
Nominal current 21.4 A
Speed 1450 rpm
Direction of rotation CW
IA/IN 7.0
Nominal power factor cos phi 0.85
Operating mode S1 (continuous operation)
Enclosure IP 55
Ex-protection none
Type of mounting IM V1
Frame size 160 M

Designation Three-phase motor for main oil pump
Speed 1450 rpm
IA/IN 7.0
Enclosure IP 55
Ex-protection none
Frame size 160 M
Consumer list Project

Hydraulic Power Supply Unit HPSU Bharat Heavy Electrical Limited (India)
page 1 of 1 Date: 2015-12-15 H-10595-HA (Project: Bhadradri 3&4 (4 x 270 MW))
Designation Three-phase motor for bypass filter pump
Speed 1415 rpm
IA/IN 4.6
Enclosure IP 55
Ex-protection none
Frame size 90 S

Designation Three-phase motor for oil cooler fan
Speed 1370 rpm
IA/IN 3.8
Enclosure IP 55
Ex-protection none
Frame size 71 M

Designation Three-phase motor for bypass filter pump
Speed 1415 rpm
IA/IN 4.6
Enclosure IP 55
Ex-protection none
Frame size 90 S

Designation Three-phase motor for oil cooler fan
Speed 1370 rpm
IA/IN 3.8
Enclosure IP 55
Ex-protection none
Frame size 71 M

Signal-IO-List
Signal‐IO‐List 1400655 Rev. 1 (Bhadradri) Page 1
Equipment Hydraulic Power Supply Unit HPSU and Actuators
Client: Bharat Heavy Electricals Limited (India)
Customer Doc. No. Rev. 1 01.02.2016
BOMAFA Doc. No. IO 1400655 (Bhadradri 3&4) Rev. 0 15.12.2015
Serial Signal
KKS No. No.
Description Qty. Signal Type Signal Source Interface Signal = 0 Status (Off) Signal = 1 Status (On)
Destination
1. Signals from the BHEL's DCS to the Electric Terminal Boxes at the Hydraulic Actuators of LP Bypass Stop Valve System and LP Bypass control Valve System
Quick Close Command 1.1 for LP Bypass LP Bypass Stop Valve1 quick close LP Bypass Stop Valve1 normal open /
MAN41 AA013 1,1 1 DO 24 V DC DCS JB‐701.1 TSV 351
Stop Valve1 function close function
Normal Open / Close Command for LP LP Bypass Stop Valve1 normal close LP Bypass Stop Valve1 normal open
MAN41 AA011 1,3 1 DO 24 V DC DCS JB‐701.1 PV 350
Bypass Stop Valve1 function function
Normal Open / Close Command for LP LP Bypass Stop Valve2 normal close LP Bypass Stop Valve2 normal open
MAN51 AA011 1,6 1 DO 24 V DC DCS JB‐701.1 PV 350
Bypass Stop Valve2 function function
Control Enabling Command for LP Bypass LP Bypass Control Valve1 normal LP Bypass Control Valve1 normal
MAN42 AA011 1,7 1 DO 24 V DC DCS JB‐702.1 IL 353
Control Valve1 position control function enabled position control function locked
Position Control Signal for LP Bypass 30 mA = LP Bypass Control Valve1 open ‐30 mA = LP Bypass Control Valve1 close
MAN42 AA012 1,8 1 AO 4 ‐ 20 mA DCS JB‐702.1 SV 310
Control Valve1 function function
Control Enabling Command for LP Bypass LP Bypass Control Valve2 normal LP Bypass Control Valve1 normal
MAN52 AA011 1,9 1 DO 24 V DC DCS JB‐702.1 IL 353
Control Valve2 position control function enabled position control function locked
Position Control Signal for LP Bypass 30 mA = LP Bypass Control Valve2 open ‐30 mA = LP Bypass Control Valve2 close
MAN52 AA012 1,10 1 AO 4 ‐ 20 mA DCS JB‐702.1 SV 310
Control Valve2 function function
2. Signals from the Electric Terminal Boxes at the Hydraulic Actuators of LP Bypass Stop Valve System and LP Bypass control Valve to the Main Control System DCS
MAN41 CG101C 2,1 Limit Switch LP Bypass Stop Valve1 Close 1 DI dry contact Limit Switch JB‐701.1 DCS LP Bypass Stop Valve1 not closed LP Bypass Stop Valve1 closed
MAN41 CG101E 2,2 Limit Switch LP Bypass Stop Valve1 Close 1 DI dry contact Limit Switch JB‐701.1 DCS LP Bypass Stop Valve1 not closed LP Bypass Stop Valve1 closed
MAN41 CG101B 2,3 Limit Switch LP Bypass Stop Valve1 Open 1 DI dry contact Limit Switch JB‐701.1 DCS LP Bypass Stop Valve1 not opened LP Bypass Stop Valve1 opened
MAN41 CG101D 2,4 Limit Switch LP Bypass Stop Valve1 Open 1 DI dry contact Limit Switch JB‐701.1 DCS LP Bypass Stop Valve1 not opened LP Bypass Stop Valve1 opened

Proximity
MAN41 CL011 2,5 LEAKAGE OIL SENSOR LPBP SV1 1 DI 24 V DC JB‐701.1 DCS NO Oil Leakage in the Oil Tub Oil Leakage in the Oil Tub ‐ warning
Switch
MAN51 CG101C 2,6 Limit Switch LP Bypass Stop Valve2 Close 1 DI dry contact Limit Switch JB‐701.2 DCS LP Bypass Stop Valve2 not closed LP Bypass Stop Valve2 closed
Page 1 of 3
Serial Signal
KKS No. No.
Destination
MAN51 CG101E 2,7 Limit Switch LP Bypass Stop Valve2 Close 1 DI dry contact Limit Switch JB‐701.2 DCS LP Bypass Stop Valve2 not closed LP Bypass Stop Valve2 closed
MAN51 CG101B 2,8 Limit Switch LP Bypass Stop Valve2 Open 1 DI dry contact Limit Switch JB‐701.2 DCS LP Bypass Stop Valve2 not opened LP Bypass Stop Valve2 opened
MAN51 CG101D 2,9 Limit Switch LP Bypass Stop Valve2 Open 1 DI dry contact Limit Switch JB‐701.2 DCS LP Bypass Stop Valve2 not opened LP Bypass Stop Valve2 opened

Proximity
MAN51 CL011 2,10 LEAKAGE OIL SENSOR LPBP SV2 1 DI 24 V DC JB‐701.2 DCS NO Oil Leakage in the Oil Tub Oil Leakage in the Oil Tub ‐ warning
Switch
Position Feedback Signal of LP Bypass 4 mA = LP Bypass Control Valve close 20 mA = LP Bypass Control Valve open
MAN42 CG001A 2,11 1 AI 4‐20 mA Pos Transmitter JB‐702.1 DCS
Control Valve1 position position
Position Feedback Signal of LP Bypass 4 mA = LP Bypass Control Valve close 20 mA = LP Bypass Control Valve open
MAN52 CG001A 2,12 1 AI 4‐20 mA Pos Transmitter JB‐702.2 DCS
Control Valve2 position position
Diff Press Filter at LP Bypass Stop Valve1 Diff Press Press Filter at LP Bypass Stop Valve1 not Press Filter at LP Bypass Stop Valve1
MAN41 CP021 2,13 1 DI dry contact JB‐701.1 DCS
> max Switch clogged clogged
Diff Press Filter at LP Bypass Stop Valve2 Diff Press Press Filter at LP Bypass Stop Valve2 not Press Filter at LP Bypass Stop Valve2
> max Switch clogged clogged
Diff Press Filter before Servo Valve for LP Diff Press Press Filter before Servo Valve not
MAN42 CP021 2,15 1 DI dry contact JB‐702.1 DCS Press Filter before Servo Valve clogged
Bypass Control Valve1 > max Switch clogged
Diff Press Filter before Servo Valve for LP Diff Press Press Filter before Pilot of Servo Valve Press Filter before Pilot of Servo Valve
Bypass Control Valve1 > max Switch not clogged clogged
Diff Press Filter before Servo Valve for LP Diff Press Press Filter before Servo Valve not
MAN52 CP021 2,17 1 DI dry contact JB‐702.2 DCS Press Filter before Servo Valve clogged
Bypass Control Valve2 > max Switch clogged
Diff Press Filter before Servo Valve for LP Diff Press Press Filter before Pilot of Servo Valve Press Filter before Pilot of Servo Valve
Bypass Control Valve2 > max Switch not clogged clogged
3. Signals from the Electric Terminal Cabinet at the HPSU to the Main Control System DCS
Press HPSU Accumulator pressure 0‐600 bar = 4 ‐ 20
MAX05 CP003 3,1 Pressure Transmitter Operating Pressure 1 AI 4‐20 mA DCS Accumulator pressure << min
Transmitter terminals mA
MAX05 CP001 3,2 Pressure Transmitter Main Pump 1 1 AI 4‐20 mA DCS Main Pump 1 pressure << min
MAX05 CP002 3,3 Pressure Transmitter Main Pump 2 1 AI 4‐20 mA DCS Main Pump 2 pressure << min
Temp HPSU
MAX05 CT001 3,4 Temperature Transmitter Oil Tank 1 AI 4‐20 mA DCS Oil Temperature Signal failure Oil Temperature ‐30 ‐ 100°C = 4 ‐ 20 mA
Transmitter terminals
Temp HPSU
MAX05 CT002 3,5 Temperature Transmitter Oil Tank 1 AI 4‐20 mA DCS Oil Temperature Signal failure Oil Temperature ‐30 ‐ 100°C = 4 ‐ 20 mA
HPSU
MAX05 CP020 3,6 Pressure Switch Oil Cooler Pump 1 1 DI dry contact Press Switch DCS Oil Coller Pump 1 pressure < min Oil Cooler Pump 1 pressure available
terminals
HPSU
MAX05 CP021 3,7 Pressure Switch Oil Cooler Pump 2 1 DI dry contact Press Switch DCS Oil Coller Pump 2 pressure < min Oil Cooler Pump 2 pressure available
terminals
Page 2 of 3
Serial Signal
KKS No. No.
Destination
HPSU
MAX05 CP026 3,8 Pressure Switch Oil Regeneration Unit 1 DI dry contact Press Switch DCS Oil Regeneration Unit pressure < min Oil Regeneration Unit pressure available
terminals
Diff Press HPSU
MAX05 CP011 3,9 Diff Press Filter at Main Pump 1 > max 1 DI dry contact DCS Press Filter at Main Pump 1 not clogged Press Filter at Main Pump 1 clogged
Switch terminals
Diff Press HPSU
MAX05 CP012 3,10 Diff Press Filter at Main Pump 2 > max 1 DI dry contact DCS Press Filter at Main Pump 2 not clogged Press Filter at Main Pump 2 clogged
Switch terminals
Level HPSU
MAX05 CL001 3,11 Oil Level Transmitter 50 < min 1 AI 4‐20 mA DCS Oil Level < min (warning) Oil Level sufficient ‐ NO warning
Level HPSU
MAX05 CL001 3,12 Oil Level Transmitter 50 << min(*1) 1 AI 4‐20 mA DCS Oil Level << min (alarm ‐ pumps OFF) Oil Level sufficient ‐ NO alarm
Level HPSU
Level HPSU
Level HPSU
Level HPSU
Diff Press Filter at Oil Cooler Pump 1 > Diff Press HPSU Press Filter at Oil Cooler Pump 1 not
MAX05 CP013 3,17 1 DI dry contact DCS Press Filter at Oil Cooler Pump 1 clogged
max Switch terminals clogged
Diff Press Filter at Oil Cooler Pump 2 > Diff Press HPSU Press Filter at Oil Cooler Pump 2 not
MAX05 CP014 3,18 1 DI dry contact DCS Press Filter at Oil Cooler Pump 2 clogged
max Switch terminals clogged
HPSU Press Filter at Oil Regeneration Unit not
MAX05 CP027 3,19 Return Line Filter Oil Regeneration Unit 1 DI dry contact Press Switch DCS Filter at Regeneration Unit clogged
terminals clogged
4. Signals from the BHEL's DCS to the Electric Terminal Boxes at the HPSU
Oil flow under pressure from pump 1 in HPSU p > 165 bar: Pressure‐free circulation p < 160 bar: Oil flow under pressure into
MAX05 AA011 4,1 1 DO 24 V DC DCS TSV 320
hydraulic system terminals from the oil pump back into the tank. the hydraulic system
Oil flow under pressure from pump 2 in HPSU p > 165 bar: Pressure‐free circulation p < 160 bar: Oil flow under pressure into
MAX05 AA012 4,2 1 DO 24 V DC DCS TSV 321
hydraulic system terminals from the oil pump back into the tank. the hydraulic system
Notes: (*1) set point for command "pumps OFF" (oil level <<min) at 9 mA
Legends: DI Digital Input (from HPSU to DCS) HPSU Hydraulic Power Supply Unit

DO Digital Output (from DCS to HPSU) DCS Main Control System
AI Analog Input (from DCS to HPSU) TSV Solenoid Valve
Analog Output (from HPSU to DCS) 4‐20
AO IL Interlocking Valve
mA ‐ 2 wire (24 V DC)
SV Servo valve
Page 3 of 3
Instrument List
Instrument List 1400655 Bhadradri Rev. 2 Page 1
Client: Bharat Heavy Electricals Limited (India) Rev. 2 Date 28.04.2016
Customer Doc. No. Rev. 1 Date 04.02.2016
BOMAFA Doc. No. IN 1400655 (Bhadradri 3&4) Rev. 0 Date 14.12.2015
Signal
Item Qty./ Process Calibration Physical Set Power Power
KKS No. No.
Mounting Location HPSU Description Unit Function connection Range Range
Unit (Range) Unit point Supply Source
Destinati
on
Instruments for Hydraulic Power Supply Unit
Shridhan ‐ Magnetic Float Operated:
DN 65 Flange
MAX 05 CL 001 50 FLX, Stem Length 390 mm, Flange Size Oil Level Transmitter 1 Oil Level Transmitter 0 ‐ 290 mm 0 ‐ 290 mm Level 4 ‐ 20 mA 24 V DC DCS DCS
Connection
DN65, ANSI B16.5, #150
DN 65 Flange
Connection
DN65, ANSI B16.5, #150
DN 65 Flange
Connection
DN65, ANSI B16.5, #150
Electronic
Female cable
Temperature Hydraulic Oil mA & PNP
MAX 05 CT 001 55 Hydac ETS 3866‐3‐000‐000 1 connection 0 to 100 º C ‐ 30 to 150 º C º C 4 ‐ 20 24 V DC DCS DCS
Transmitter cum Temperature Switch
M12X1, 4 pole
Switch
Electronic
Female cable
Temperature Hydraulic Oil mA & PNP
MAX 05 CT 002 56 Hydac ETS 3866‐3‐000‐000 1 connection 0 to 100 º C ‐ 30 to 150 º C º C 4 ‐ 20 24 V DC DCS DCS
Transmitter cum Temperature Switch
M12X1, 4 pole
Switch
HART Type Pressure 1/2‐14 NPT
MAX 05 CP 001 180 ABB 266HSHVKBA1L1B6 1 HPSU Pressure 0 ‐ 250 0 ‐ 600 Bar 4 ‐ 20 mA 24 V DC DCS DCS
Transmitter Female
Transmitter Female
Transmitter Female
Pressure Switch Oil 1/4" BSP
MAX 05 CP 020 183 Nautilius XMLA 020A2S11 Pressure Switch 1 < 2 bar 0 ‐ 20 Bar Contact NO & NC 2 bar 24 V DC DCS DCS
Cooler Pump 1 Female
Cooler Pump 2 Female
Regenration Unit Female
Pressure Line filter Clogging Indicator Main Pump 1 Filter
MAX 05 CP 011 120 Clogging Indicator 1 G 1/2" > 5 > 5 Bar Contact CO 5 bar 24 V DC DCS DCS
VD 5 D.X /‐V‐L24 Clogging Indication
Pressure Line filter Clogging Indicator VD Main Pump 2 Filter
MAX 05 CP 012 121 Clogging Indicator 1 G 1/2" > 5 > 5 Bar Contact CO 5 bar 24 V DC DCS DCS
5 D.X /‐V‐L24 Clogging Indication
Page 1 of 3
Signal
KKS No. No.
Destinati
on
Clogging indication on
Return Line filter Clogging Indicator VR 2
MAX 05 CP 013 65 Clogging Indicator 1 filter Oil Cooler Pump G 1/2" > 2 > 2 Bar Contact CO 2 bar 24 V DC DCS DCS
D.X /‐V‐L24
1
MAX 05 CP 014 66 Clogging Indicator 1 filter Oil Cooler Pump G 1/2" > 2 > 2 Bar Contact CO 2 bar 24 V DC DCS DCS
D.X /‐V‐L24
2
MAX 05 CP 027 179 Clogging Indicator 1 filter Oil Regeneration G 1/2" > 2 > 2 Bar Contact CO 2 bar 24 V DC DCS DCS
D.X /‐V‐L24
1
HPSU Operating
MAX 05 CP 501 186 WIKA‐Hydac 233.50 / 100 / 250 Pressure Gauge 1 G 1/2" 0‐280 0‐280 Bar
Pressure
Pressure at Oil Cooler
Pump 1
Pressure at Oil Cooler
Pump 2
Pressure at Oil
Regeneration Unit
Oil Pressure at
Accumulator 810
Oil Pressure at
Accumulator 811
Banjo Bolt
MAX 05 CL 501 30 Hydac FSA‐254‐2.X/‐/12 Oil Level Gauge 1 Oil Level in Oil Tank 10 0‐400 0‐400 mm
thread M12
Hydraulic Control Block for LP Stop Valve
Clogging Indication of
MAN 41/51 Pressure Line filter Clogging Indicator
320 Clogging Indicator 1 Filter for LP Stop Valve G 1/2" > 5 > 5 Bar Contact CO 5 bar 24 V DC DCS DCS
CP021 VD 5 D.X /‐V‐L24
> max
MAN 41/51 End position Open LP
501 Honeywell GLAA01A1B Limit Switch 1 1/2‐14 NPT > Max Position Contact NC 24 V DC DCS DCS
CG101B Stop Valve
MAN 41/51 End position Open LP
502 Honeywell GLAA01A1B Limit Switch 1 1/2‐14 NPT > Max Position Contact NC 24 V DC DCS DCS
CG101D Stop Valve
MAN 41/51 End position Close LP
503 Honeywell GLAA01A1B Limit Switch 1 1/2‐14 NPT < Min Position Contact NC 24 V DC DCS DCS
CG101C Stop Valve
MAN 41/51 End position Close LP
504 Honeywell GLAA01A1B Limit Switch 1 1/2‐14 NPT < Min Position Contact NC 24 V DC DCS DCS
CG101E Stop Valve
MAN 41/51 Oil Leakage Switch (Oil Oil
505 IFM KI5038 Oil Leakage Sensor 1 M30x1.5 Yes / No Contact NC 24 V DC DCS DCS
CL011 Tub) Leakage
Page 2 of 3
Signal
KKS No. No.
Destinati
on
Hydraulic Control Block for LP control valve
MAN 42/52 Pressure Line filter Clogging Indicator
321 Clogging Indicator 1 Filter for Servo Valve > G 1/2" > 5 > 5 Bar Contact CO 5 bar 24 V DC DCS DCS
CP021 VD 5 D.X /‐V‐L24
max
MAN 42/52 Filter (Pilot Oil) Clogging Indicator
322 Clogging Indicator 1 Filter for Pilot of Servo G 1/2" > 5 > 5 Bar Contact CO 5 bar 24 V DC DCS DCS
CP022 VD 5 D.X /‐V‐L24
Valve > max
Position of LP Control
MAN 42/52
581 Baluff BLT7 ‐ E170 M0200 B S32 Position Transmitter 1 Valve 0 to 100 % M18 x1.5 0 ‐ 150 mm 4 ‐ 20 mA 24 V DC DCS DCS
CG001A
Stroke
Page 3 of 3
1.7
Acceptance test documents

LPBP HPSU Document PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

LPBP HPSU Document PDF

Încărcat de

Drepturi de autor:

Formate disponibile

Documentation

Order No.: B5V6275

Bharat Heavy Electrical Limited (India)

Setting ranges of the components

Page 1 of 6 Functional description HPSU

Page 2 of 6 Functional description HPSU

Manual operated shut-off valves at the pressure filters

Controlling of the oil-air-coolers and the regeneration unit

Page 3 of 6 Functional description HPSU

Filter monitoring of the oil-air-cooling circuits and of the regeneration unit

Page 4 of 6 Functional description HPSU

Operational control of valves

Further adjustments on the valves / hydraulic cylinders could be effected as follows:

Page 5 of 6 Functional description HPSU

Page 6 of 6 Functional description HPSU

Order No.: B5V6275

Bharat Heavy Electrical Limited (India)

Page 1 / 4 Installation HPSU 2017-01-30

The filter fineness must be 10 µm.

Check if all seals are installed correctly.

Hydraulic Accumulators, Nitrogen Pressure

Page 2 / 4 Installation HPSU 2017-01-30

Page 3 / 4 Installation HPSU 2017-01-30

Correct installation increases the service life of hose assemblies:

WRONG BETTER RIGHT

Page 4 / 4 Installation HPSU 2017-01-30

Order No.: B5V6275

Bharat Heavy Electrical Limited (India)

The filter fineness must be 10 µm.

Check if all seals are installed correctly.

Page 1 / 9 Commissioning and maintenance HPSU 2017-01-30

Flushing of hydraulic components and pipework

In the following points the flushing procedure is described:

Page 3 / 9 Commissioning and maintenance HPSU 2017-01-30

1.) Hydraulic oil tank

After 6 month of operation:

Complete oil change:

The filter fineness must be 10 µm.

Check if all seals are installed correctly.

2.) Hydraulic cylinders, flexible hoses and pipes

3.) Hydraulic Accumulators, Nitrogen Pressure

Page 5 / 9 Commissioning and maintenance HPSU 2017-01-30

Page 6 / 9 Commissioning and maintenance HPSU 2017-01-30

Page 7 / 9 Commissioning and maintenance HPSU 2017-01-30

7.) Air Venting of the Hydraulic Cylinders and Pipes

Page 8 / 9 Commissioning and maintenance HPSU 2017-01-30

Page 9 / 9 Commissioning and maintenance HPSU 2017-01-30

4 First aid measures

Trade name: FYRQUEL EHC-N

5 Fire fighting measures

6 Accidental release measures

Trade name: FYRQUEL EHC-N

7 Handling and storage

8 Exposure controls and personal protection

Trade name: FYRQUEL EHC-N

9 Physical and chemical properties

10 Stability and reactivity

Trade name: FYRQUEL EHC-N

Trade name: FYRQUEL EHC-N

Trade name: FYRQUEL EHC-N

· Canadian WHMIS Classification(s): D2A

Installation Instructions Ui 600V AC

English Español Italiano