Installation Instructions

Fuel Oil Control Valve KBSD Upgrade

Introductory comment:
The purpose of this installation guide is to enable the engine crew to install the ARI Premio
retrofit solution for KBSD Burners. This instruction will describe the installation step by step.

1 Delivery Scope
This installation kit provides you with all the parts needed to successfully complete the
installation. General consumable parts might be needed such as cable ties and heat shrinkable
tubing for proper wiring.

Kit check list:

Fuel Oil Control Valve

Spool Piece
Bolts
Nuts
Gaskets
Cables, glands
Terminals for electrical termination
Documentation
PI&D, Electrical drawings, Data
Sheet, Instruction manual

2 Preparation
Before starting the installation, be sure to have all materials lined up and ready for the
installation.
Alfa Laval Aalborg recommends overhauling the flow meter while changing the oil regulating
valve, just for convenience. Alfa laval Aalborg estimates that 5 hours is required for the job.

Follow below steps for preparation:

Step A: Switch over the system to DO or MGO (if converted) to avoid cooling
down the system on HFO. Once changed over, shut down the boiler
system.
Step B: Check that the content in the kit is complete in accordance to the
order.
Step C: Find a suitable cable-route for both cables going from the valve to
the control cabinet. Dependent on production year there might be
available space in the bottom of the cabinet; otherwise
recommendation is to gain access from the back of the cabinet.
Alternatively the original signal cable to the IP Converter can be re-
used.

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Installation Instructions
Fuel Oil Control Valve KBSD Upgrade
3 Disassembling
Caution: Before replacing the parts, be sure that the system is powered off.

Step A: Shut off the air supply to Masoneilan Fuel Oil Valve [F94] and
Fairchild IP Converter [F95].
Step B: Disconnect all air-piping to Fuel Oil Valve, IP Converter and Filter
Regulators. Block the air pipes using included fitting.
Step C: Loosen the nuts on the threaded bars that hold the Fuel Oil Valve in
position and remove it.
Step D: Remove the spool piece 8 between the three-way valve F75 and the
Fuel Oil Valve.
Step E: Remove the oil flow meter. Its highly recommended to overhaul the
flow meter with new bearings and O-rings in the same process.
For burners equipped with OMG 32 (DN32) flow meters: The
temperature pocket must be removed.

With above steps completed everything within the red box should be removed.

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Installation Instructions
Fuel Oil Control Valve KBSD Upgrade
4 Installation
Installation is divided into a mechanical part 4.1 and an electrical part 4.2

4.1 . Mechanical Installation Procedure

Step A: Mount the new Spool piece to the 3-way wall F75, using a new
gasket from the kit.
Step B: Bolt the Flow meter and the oil valve together using the 4 studs
included in the set. Depending on the system it might be necessary
to shorten all four studs with approximately 1.5-2cm.
Remove the 4 studs which are holding the temperature pocket in
place.
Step C: Lower down the valve and the flow meter. Connect it at each end,
and remember to use the gaskets included in the kit.

4.2 Electrical Installation Procedure, Valve

The new valve is controlled by a 4-20mA signal coming from the Unisab controller, Analogue output
03 [AO03], and supplied with 230VAC power. See enclosed electrical drawing for details.

Step A: Unscrew the top cover on the valve.

Step B: Insert both cables through the cable lead-ins. In case the old signal
cable from the IP converter is long enough, this can be reused.
Step C: Connect both cables in accordance to enclosed electrical drawing.

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Installation Instructions
Fuel Oil Control Valve KBSD Upgrade
4.3 Electrical Installation Procedure, Control Cabinet

In the control cabinet its necessary to install a terminal for the new 230VAC
supply. This new terminal is marked as X1 on the new electrical drawing.
(On some plants you might find available terminals)

Step A: Reuse the original signal cable to the IP Converter, or install the 2
core cable w. shied from the kit. This will serve as 4-20mA signal
cable.
Step B: Install the new power supply cable in accordance with the new
electrical drawing (replacement sheets 40A & 108A.

Caution: Ensure that the new electrical connections have been established as shown on the
drawing sheet 40A included in the kit.
The actuator must be connected to earth!

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Installation Instructions
Fuel Oil Control Valve KBSD Upgrade
5 Start-up & Calibration Process
This chapter contains initial setup processes of your Unisab Controller and the Fuel Oil Control
Valve. The purpose of the calibration is to avoid that the actuator violates the normal operation
span.

5.1 Zero and Span Calibration:

Before putting the new valve in operation a zero and span calibration is
necessary, to avoid that the actuator is damaged.

Step A: Power up the control cabinet, and wait for the system to boot.
Step B: From the Unisab Controller set the [KEY] to position LP1 (Local
Panel 1). If the key is at [PC], release it and try again.
Step C: Browse to the menu FUEL OIL OIL FLOW. Scroll down and find
REMOTE CTRL.
Step D: Press and hold SET for 5 seconds until PASSWORD will show.
Press SET to confirm password 1234.
Step E: Change the REMOTE CTRL value from +000000 to +000001.
Now the oil flow and control output will be adjustable from the display
front, using INCREASE and DECREASE.
5.1.2 Setting Zero Calibration:
Step A: On the Unisab adjust REGULATOR OUTPUT to 0% (4mA).
Step B: Manually close the Fuel Oil Control Valve,
using the hand wheel, in case its not fully
closed.
Step C: Adjust N until the valve opens slightly.
Then adjust counter clock wise until both
red and green led are off. Now the valve is
in neutral position.

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Installation Instructions
Fuel Oil Control Valve KBSD Upgrade
5.1.3 Setting Span:
Step A: On the Unisab adjust REGULATOR OUTPUT to 100% (20mA)
The valve will start to travel. Once it stops, open it fully, using the
manual handle.
Step B: On the Fuel Oil Control Valve (valve fully open): Adjust S counter
clockwise until the actuator moves a small distance towards closed.
Then re-adjust S until both LEDS are off.

To complete the calibration put back the oil flow in automation by changing
REMOTE CTRL back to +000000 and press SET.

5.2 Adjusting Oil Factor

Adjustment of oil correction is necessary. This is done from the Engine

Control Room PC.

Use below graphic overview to change the values.

Change of the correction factors for oil.

New correction factors to be linear

Linear

If you require further technical assistance, please do not hesitate to contact your local Alfa
Laval Aalborg Support Centre.

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