> Hada Boiler HANDLING MANUAL FOR MARINE BOILER TORTOISE EncIneERING CO., LTD. 700, KITAGAWARA, MASAKI-CHO, IYO-GUN, EHIME PREF, 791-8181 JAPAN ‘TRL +81-89-984-1851 FAX 481-89-984-8988 SRM 200751 AFOREWORD ‘Thank you very much for employing our beiler for your ship. Recently, the development of equipment for ship, boilers above all, has been repaid in its automation process. However, the basic ways of maintenance and control of the boiler itself has remained almost the same as before. ‘This Instruction Manual mainly deseribes how the beginner should operate the boiler, and how the user should carry out maintenance so that the boiler may be operated in its best conditions. Please read this Instruction Manual before use, so that. the boiler can be operated safely, and efficiently.CHAPTER 1 qa 12 138 14 15 CHAPTER 2 21 22 23 fo a Sea 3 Pewee CHAPTER 3 31 32 33 84 85 36 CONTENS HOW TO OPERATE Preparation for Operation ~~ Increasing Steam Pressure~ When Steam Pressure Increases When Steam Is First Supplied. When Steam Is Supplied~ FAILURES IN OPERAION, AND COUNTERMEASURE, Priming and Foaming: Rumbling Boiler ~ Damages to Boiler Proper Swelling and Collapse by Overheat, Short, Water ~ Accidental Increase of Boiler Water ~ Broken Smoke Tube Water Level Gauy Pressure Gauge Blow-off Valve Avoiding OverLoad Operation: FEED WATER AND BOILER WATER Why Water Treatment. Is Necessary Impurities Contained in Feed Water and Boiler Water ~ Boiler Proper Corroded by Boiler Water ~ Boiler Seale, Mud Drift, Condensed Boiler Water Limit. Values for Feed Water and Boiler Water Water Control and Water Treatment:CHAPTER 1 HOW TO OPERATE, 1.1 Preparation for Operation 118 lid LLB Make sure no fault is detected in the following units before ignition. Water level gauge After confirming that the drain cock is completely closed, and that the gauge cocks on the upside and downside of the water level gauge, and the stop valve of the water level gauge are all opened to the full to allow a completely free flow, make sure that, the correct, water level of the boiler drum is indieated by the water level gauge. This should be identified as the normal water level. However, it is essential that the water level never goes below the safety water level even when it fluctuates temporarily due to inerease of boiler water temperature, foaming by evaporation, or due to changes in water level as soen in starting to circulate boiler water, which may occur in case an exhaust gas economizer in installed. It is also important to supply water adequately, so that its level may stay within the water control range, not filling the scope of the water level gauge to the full. Pressure gauge Make sure that the rot cock is opened to the full, and that the pointer stands at level The pressure gauge, which is positioned in a low position ease to see, will indicate a water level a little higher than the true level due to the head pressure inside the steam pipe (0.0981MPa per head pressure 10m). Some type of pressure gauge has its head pressure regulated. If, however, the pointer drifts by 0.05-0.07 MPa when the pressure is zero, replace ar correct it, Blow-off valve Make sure that the valves in the sides of the boiler drum, middle valves and blow-off valve outside the ship are all completely closed. The leakage from the sides of the boiler drum should be checked by touching the conductor pipe. Water feed valve Keep the feed water stop valve always opened to start feeding water any time for adjusting the water level. Close the feed water check valve to a degree not affecting the capacity of feed water, so that the damage of the valve seat, or disc can be minimized when it is activated by feed water. Steam stop valve By opening closing the handlo, make sure that the valve is completely closed. If the dise diffors in material from the stem, unequal expansion could make it difficult to open or close the valve. Use an appropriate torque to close such valve,116 LLT Safety valve Make sure that no fault is detected in the manual valve opening devise, and that the drain pipe of the body is opened. Air vent valve Open the air vent valve to the full. When steam is first generated, close the air vent valve to the full after confirming that the air inside the boiler drum has been completely released. Other units To avoid failure during operation, cheek thoroughly each of the other units such as feed water, ventilation, combustion, ete, and automatic controls, air duet, the damper of uptake, ete. 1.2 Increasing Steam Pressure (Cold Start) 121 122 ‘To avoid excessive expansion caused by the difference in temperature of each section of the boiler drum, it is essential to increase the FO consumption slowly, taking enough time. (Carry out intermittence combustion with minimum flow rate of FO.) ‘The time needed to raise the steam pressure to the specified value varies according to each type and capacity of the boiler, or each temperature of the water supplied. It is necessary, above all, to raise the pressure slowly, taking enough time, when cold water is to be warmed, The small size oylindrical boiler (Type of MKSC or MVS) will need at least 4 hours, lange size cylindrical boiler (Type of MVW) will need 6 houre or more. When especially increasing the boiler pressure up to 0.1MPa don't fail to take 2 hours (Type of MKSC or MVS) or 3 hours (Type of MVW). Negligence in such care may lead to cracks in the boiler drum, and such cracks in the water tube, smoke tube or any joint may lead to a leakage, resulting in the rupture of the boiler in the most serious ease Other instructions to follow in increasing the pressure will be describes in the following paragraphs: Air vent, When the steam is first generated, and the air inside the boiler has been exhausted enough, the air vent valve shall be totally closed. Checking leakage When the steam is generated, and the pressure starts to rise, ensure the water level again Chock if any leakage occurs in water level gauge, blow-off valve, each cover and other. If any leakage is detected, take corrective actions ineluding re-tightening,12. Re+tightening Even if no leakage occurs in the manhole cover, each valve or cock, rettighten as required every part that is fastened with packing. * Carry out increase the boiler pressure by Cold Start procedure when having repaired with the fireproof material. 1.8 When Steam Pressure Inereases 13. 1 Adjustment of combustion When the steam pressure is applied, note how it rises, Adjust, combustion slowly, s0 that the steam pressure may not rise rapidly. Monitoring water level Check water level of water gauges several time when increasing of boiler pressure. Carry out performance test of glass water gauge several times so as to correctly read off water level Removing foreign matters Generally in initial stage of combustion, it is necessary to remove foreign matters form the boiler drum, When the pressure reaches about 1/4 of the normal working pressure, stop combustion temporarily, drain the boiler water from scum and bottom in order by opening/elosing the blow-off valve. ‘The boiler water shall be drained to a degree that it can be detected by water level gauge, and shall be re-filled up to the normal water level as a referenee. 1.4 When Steam Is First Supplied When the steam pressure reaches the specified value, and the steam is first used, pay enough attention to the following things If the main or auxiliary valve is opened, the steam that comes out will be eooled and become drain. This drain and the steam blows away the drain accumulated in the steam pipe, causing a water hammer which could destroy the steam pipe system and other units. ‘To prevent such accidents, open the steam valve a little first to warm up the inside of the pipe, and then exhaust the drain sufficiently by way of the drain valve of the pipe system. Open the steam valve as slowly and quietly as possible after the pipe system becomes hot, enough. 1.5 When Steam Is Supplied After completing the operations mentioned in the paragraphs do far, steam is supplied to each unit, and the boiler enters into a normal operation. To supply steam safely, and efficiently, necessary instruction will be given in the following paragraphs:1s. 16. 1 2 Adjustment of combustion The boiler must. be warmed, so that a uniform pressure is always kept, Violent changes in pressure may lead to a damaged boiler. The consumption of steam seldom stays equal throughout the day. If the consumption of steam load varies, combustion must also be changed, which will in turn change the volume of air to be sent. ‘The degree of openness of the damper must also be adjusted accordingly. Negligence in the adjustment may lead to an incomplete combustion and surplus of air, affecting the boiler efficiency adversely. Confirmation of water level The most important thing in operating a boiler is how to keep the boiler water stable, and prevent the water surface from falling below the safety low level. No matter how functional the automatic alarm system, automatic feed water system or remote indicator of water level, ete. may be, don't trust them 100percent. It could be dangerous. Be sure to confirm the water level regularly the water level gauge. Keep the water level gauge always clean, If it is fouled, replace or clean it, If any leakage oceurs in the water level gauge, cock(s) or connecting pipe, the correct water level may not be displayed. In such case, replace affected component immediately. (a) Testing water level gauge ‘The water level gauge in operation shalll be tested at lease deily. If any irregularity is detected in the water level, and if, for example, a low water level is suspected, tast it 8 required. () Blow -off test of water column If the water level gauge is installed on the water column, such water column shall be tested in a blown-off test, In this type of construction, a long connecting pipe and stop valve are used, and seale, mud and other foreign matters are likely to be accumulated. inside the connecting pipe, or a malfunction of a valve could lead to an error in the readings of the water level gauge, By carrying out a blow-off test before testing water level gauge, the dirt: from the water side passage and water column can be prevented from drifting into the water level gauge. Pressure gauge Pressure gauge shall be kept always clean, If any error occurs in its readings, such pressure gauge shall be replaced immediately. If priming or foaming occurs inside the boiler, it is suspected that the pressure gauge is clogged with scale, resulting in the difference between the reading of the pressure gauge and the pressure inside the boiler. Ploase note such an accident could happen in such a case.1.54 Safety valve 16. 5 {a) Confirmation of operations If the safety valve blows off, record the opening pressure and closing pressure by checking the pressure gauge, and then make sure that operation is normal. %) When valve is not activated If the valve does not blow off even when it reaches the opening pressure, blow off the valve temporarily by the manual lever, and then let the valve blow off automatically. If the valve does not blow off again, it shall be cleaned or repaired. (©) Dealing with leakage If the valve leaks below the closing pressure, change the contact of the blow-off valve slightly by the manual easing lever, If the leakage is not stopped, stop the operation of the boiler immediately, and repair the valve, Never tap or pry the safety valve in any case. (a) Blow-off test. and water level ‘The blow-off test of safety valve shall be carried out by an engineer accustomed to the structure of such safety valve, In this, don't raise the water level to the to 2/8 or more of the visible part of the water level gauge. Blow-off of boiler water Blow off the boiler water 30 minutes after stopping the combustion, or when the lease amount of steam is being used if the combustion can not be stopped. When the density of the boiler water gauge tends to increase, as in a case when low quality of water is supplied, or when more of precipitation is detected, blow off the boiler water more often. If, during the blow-off, the water level of the water level gauge con not be identified from the point of blow-off, keep communication with another worker who can see the water level, and perform such blo off, Never do any other thing until the blow-off is completed. 1.5.6 Soot blowing Carry out soot blowing as required according to the degree of adhered soot. (a) Oil fired side soot blower a. Carry out soot blowing after stopping the combustion. b. Handling(GH25 or SB25) + Exhaust drain properly. + After removing the advancing stopper, push the handle forward. + To prevent reaction by jet stream, set the stopper in the stud bolt, and then fix it with safety stopper. + Open the steam stop valve to the full slowly, and then turn the handle immediately. + After maintaining the jet stream for a fow minutes, close the steam valve, + Release the safety stopper, and then the stopper to let the handle come back. + Set the advancing stopper to prevent the nozzle from coming into the combustion chamber,{) Exhaust gas side soot blower a. Handling Exhaust drain properly. Open the steam stop valve to the full slowly, and then turn the handle immediately. While confirming the bolt indicating the nozzle direction, apply the jet stream mainly upon the smoke tube, ‘Turn the nozzle 360 degrees at a rate of 9:1, and apply the jet stream upon the internal walls of the smoke box. After maintaining the jet stream for a fow minutes, close the steam valve. (©) Instructions about jetting medium a. Steam Exhaust drain properly, and operate the soot blower after warming up the pipe. After blowing soot, turn the stop valve and steam stop valve both "Closed". “Open” the drain valve, so that any more of drain may not be accumulated, To carry out the soot blowing efficiently, keep the pressure as high as possible, b. Compressed air Be sure to change over the air reservoir valve. (1 unit of main air reservoir is used.) The air reservoir shalll be used at a pressure of more than 0.98MPa Be sure to close the stop valve and root valve.CHAPTER 2 FAILURES IN OPERATION, AND COUTERMEASURE 2.1 Priming and Foaming 218 Priming is a phenomenon in which some portion of the boiler water is carried away with the steam when boiled vehemently. Foaming is a phenomenon in which a mountain of bubbles is formed in the boiler when such bubbles are less likely to break up due to a stronger surface tension of the boiler water that becornes more condensed by and by. In some serious case of the above mentioned phenomenon, a portion of the boiler water is carried away with the steam. Hazards by priming and foaming (a) The level of the boiler water fluctuates violently, and it is difficult to identify the water level in the water level gauge. {b) Safety valve may be fouled, or the connecting hole of the pressure gauge may be clogged with seale or other foreign matters, or boiler water may come into the vent hole of the water level gauge, All these things could degrade the performance of each unit, (©) The portion of the boiler water carried away with the steam may be accumulated in the piping, and cause a water hammer, finally damaging the piping and each unit using such steam. (a) When priming or foaming occurs, the water level of the boiler drops suddenly, which could cause any accident due to low water levels. How priming and foaming occurs Too high water level, too rapid evaporation, too rapid inerease of steam volume used, and boiler water density excoeding a specified level may cause these phenomena, Also note that some drifting particles, organic matters, soap or oil that may be include in the boiler water could contribute to these phenomena, How to deal with problems If priming or foaming occurs, identify the true case for such problem first, and be sure to see what corrective action(s) ean be taken If'such problem occurs suddenly, restrict the combustion first, and allow the water level gauge to show the correct level. Take the following steps according for each cause of the problem: (a) When the water level is high, adjust it by blowing off the boiler water. (b) Open/close the steam valve slowly. If the problem is cased by a rapid increase of combustion load, restrict the combustion, and wait for the water level to stabilize, and then inerease the load slowly. (2) If the boiler water is of high density, repeat blow-off and feed water to decrease the density. -10-(a) [foil or fat is ineluded in the boiler water, such oil or fat secreted may be sean in the glass of the water level gauge. In such a case, stop the operation of the boiler immediately, and remove the cause for including such oil or fat, and then flush the inside of the boiler. fe) Test the safety valve, blow off the connecting pipe of the pressure gauge, and open the blow-off cocks of water level gauge and water column, and then finally cheek the normal operation of these units, 2.2 Rumbling Boiler During combustion, a rumbling sound may be heard continuously in the combustion chamber or flue, and the boiler room may reverberate with such rumbling sound. This is called "Rumbling Boiler 2.21 Causes for rumbling boiler (2) When too much water is contained in the fuel () Plue and air are mixed improperly, or combustion speed is too slow, (©) When a pocket causing current stream is produced in the flue. (a) When the sectional area of the flue varies widely, 2.22 Prevention ‘To prevent rumbling, use the fuel containing less water, and allow the combustion to complete as swiftly as possible by improving the ways of heatingffeeding the secondary air, and adjusting the ventilation, 2.8 Damages to Boiler Proper The explosion of the boiler proper will bring about the most. serious damage of all accidents. More of double-protective measures shall be taken aczordingly, The followings are the cases where the accident generally leads to a partial rupture, short of big explosion. (a) Overheat, swelling and erack of the boiler drum () Crack, leakage and overheat of the cireumferential joint of the boiler (2) Overheat, swelling, rupture and corrosive perforation of water tube (a) Corrosive perforation of smoke tube, and overheat and leakage of installed section (e) The overheat, swelling, collapse or crack of the flue and combustion chamber will need appropriate corrective action(s) However, the most important thing is how to find such fault in early stages. To do this, be sure to detect any leakage from the boiler proper early, confirm if the refractory protective material or brick wall is not damaged, and monitor any in gularity of the heating surface inside the furnace, When the accident is restricted to a partial rupture of the boiler, causing no immediate danger, take the following actions immediately after stopping the operation: oie{a) By stopping the operation of the blower, and opening the damper, release the leaked steam by way of the chimney in natural flow of air, {b) Feed enough water to keep the water level appropriate, (©) By stopping the combustion, reduce the damage to the boiler (a) Drain water after the boiler is cooled down properly. 2.4 Swelling and Collapse by Overheat. ‘These ocour when a lot of inerustation is deposited, condensed water is heated, or when ow lovel of tank water is heated (short water burning). In these cases, take the following action(s) (a) Stop the combustion, and cool the boiler as the fire door is opened. {b) In no irregularity is detected in the water level when the feed water valve is opened slightly, keep on feeding water. (©) Close the steam stop valve. (a) Wait for the pressure to fall naturally, Never blow off the safety valve, fe) Check the cause of the accident inside/outside the boiler when it is cooled down, () Repair each part as required. 2.5 Short Water (Accidental Level-down of Boiler Water) In most cases, this kind of accident is an error caused by carelessness, because no accidental lovel-down of boiler water will occur if the specified amount of supply water is always fed to the boiler, ‘The following things are suspected as possible cause for this: (a) In ease the water level indicated by the water level gauge does not fall when the water level inside the boiler is actually lowered due to clogged gauge cock of the water level gauge, or error in openingfelosing such cock or stop valve of the water level gauge. {) In case the boiler water level falls abnormally due to the leakage, slack or insufficient tightening of blow valve or cock, leakage from the boiler proper, or leakage of safety valve (In case water is supplied insufficiently due to the failure in feed water pump, feed water valve or automatic feed water control system. (@)_ Incase a load exceeding the capacity of the boiler is applied. If an abnormal level-down of the boiler water, which is caused by the above-mentioned conditions, is detected, take appropriate action(s) according to "2.3 Damages to Boiler Proper" for a partial rupture of the boiler, and take appropriate action(s) according to "24 Swelling and Collapse by Overheat" for a swelling or collapse of the boiler. If such external irregularity is not detected, determine if the water level has been lowered even below the safety low level, If the water level falls below the safety low level. 12estimate how long the water level is being lowered below such safety level. If such water level stays below the safety low level for only for a short time, simply increase the feed water. Or if the heating surface is heated, take more drastic action(s) according to the above items 2.3 and 24, In many cases, such reduced water level by it self inflicts less damage to the boiler, while careless water supply leads more often to damages, 2.6 Accidental Increase of Boiler Water In the water level is too high, stop the combustion temporarily, and open the blow-off valve slightly to lower the water level to the normal level 2.7 Broken Smoke Tube ‘The possible causes for damaged water tube and smoke tube have already been described. If any leakage occurs due to damaged smoke tubs of a cylindrical boiler or vertical boiler, such leakage can be stopped by inserting a plug (ube stopper), excluding the ease where the leakage occurs in the mount of tube end(s) or tube plate, ‘The most important thing in using this is to clean the inside of the tube by a brush in advance, and examine if no burr is found in the damaged part, so that nothing may interfere with the stopper being inserted. Also pay attention not to be burned when inserting such stopper, If any leakage is detected during voyage, service the tube stopper for emergency use first, and replace the smoke tube with a new one when the ship enters the next port, 2.8 Water Level Gauge 28.1 Drain To avoid danger in draining the fluid inside the water level gauge, 9° be sure to install a drain piping. elie Test of water level gauge Keep the stop valves on upside and downside, and the drain valve ® opened. Remove air inside the water level gauge by opening by the upper valve (@) slowly to the full, and elose the drain valve STOP VALVE (Ox) ©. Then the pressure in the water level gauge will rise immediately. When the pressure has risen, open the lower valve @) slowly. Then soe PIT the water flows in immediately, and the water level will be Fie indicated soon Laee288 Why water level is not indicated, and how to deal with it, (a) In case check ball is activated: Close the bottom calve @ temporarily, and open the handle by half turn, and then leave it for a while, {b) In case the pipe is clogged with foreign matters Clean the pipe, Maintenance of water level gauge When re-tightening the water level gauge, drain first the fluid or drop down pressure inside the water level gauge via the drain valve by closing the stop valve or upperfower cocks Such re-tightening shall be done zigzag in the order shown in Fig.2, where the amount of tightening bolts each time shall be striated to 10 pereent or less, and all the bolts (nuts) shall be tightened uniformly. Also re-tighten SQGOGGOO @COO008 the screws periodically: Pig 2 2.9 Pressure Gauge Pressure gauge is subject to an error in operation due to the fatigue of the pressurized material when it is used for a long time. Pressure gauge should indicate zero when no pressure is applied, but it may not return to the zero position in some case, In another case, some pressure gauge indicates differently from other ones that, are equal in their indication when pressure is increased. In these cases, replace such pressure gauge with a new one, In still another case, the pointer of the pressure gauge may be too slow to rise, and jump suddenly when tapped lightly with finger tip. In this, too, the pressure gauge is broken, and must be replaced. Pressure gauge is not something that should be replaced when it is broken, but something that should be replaced periodically in a specified period of time. 2.10 Blow-olf Valve The blow-off valve may sometimes be clogged with the seale in the boiler. To prevent: the valve from being clogged, blow off the boiler water every 24 hours regardless of the density of the water. If such valve is clogged, reduce the pressure to "0", and cool the water temperature to a safe level. Then, remove the blow-off pipe from the flange, and open the valve slowly. Now you can rake out the scale bit by bit by inserting a thin rod by way of the flange hole, If any amount of boiler water flows out, close the valve immediately, and install the blow-off pipe, and then blow off the water by opening the valve to the full. However, never take this method when any pressure is left inside, or when the water is boiling, The facing-up of the blow-off valves shall be dono as often as the chanes is given, even when no leakage is detected, so that the proper function is maintained. The gland packing shalll be replaced each time in such facing-up, When installing the gland packing, an allowance for re-+tightening shall be left, -14-2.11 Avoiding Overload Operation 2.11.1 Heavy oil fired side ‘To avoid an overload operation, don't adjust the oil amount of the combustion system to a value exceeding the planned values specified in the drawings and Instruction Manual. Overload operation may lead to a boiler failure. 2.11.2 Main engine exhaust gas side of eomposite type boiler Operate the boiler under the conditions for exhaust gas remaining within the range of planned values specified in the drawings, Any negligence, in this ease, may lead to sineulation pump, degraded performance of drain cooler, water feed pump, economizer ete... or a boiler failure could result. -15-CHAPTER 3 FEED WATER AND BOILER WATER 3.1 Why Water Treatment Is Necessary When the water sent to the boiler tank is evaporated by combustion heat, the impurities contained in the water are always left behind. As the combustion and evaporation continue, the impurities contained in the boiler water will be inerease indefinitely, Some of these impurities, insoluble in the water, are deposited on the bottom as inerustation (scale) and mud, while some of them, light in weight, may float on the surface of the water. Other impurities dissolved in the water will increase the density of the water as it grows in quantity, These phenomena may lead to the corrosion and eracks of the boiler proper, flue and smoke tube, which will in turn degrade the efficiency of heat conduction, causing the boiler overheated. The boiler water, too dense, will contribute to a carry over that takes a portion of water up in evaporation, where water is contained in the steam, All this will lead to a heat loss, and any other problems difficult to cope with. If gas such as oxygen or carbon dioxide is included in the feed water, such substanee will lead to a corroded boiler. The boiler is more corroded as the temperature and pressure of the steam used are higher. In this regard, it is obvious that the quality of the boiler water brings about an extensive influence, influence, and it is necessary that the feed water, and the way of such feed waters should be improved in any way to prevent its quality from being deteriorated. Boiler water treatment is absolutely necessary for the former, and feed water treatment, is absolutely necessary for the latter, 3.2 Impurities Contained in Feed Water and Boiler Water 3.2.1 Impurities ineluded undisclosed Inorganic matters are mud, clay, sand, iron rust, ete, Organic matters are animal and plant, substances such as starch powder, tannin, oil and fats, ete. which react with carbon, and include hydrogen, oxygen and nitrogen, Other types of oil and fats are also included. Inorganic matters and organic matters do precipitate, while some of the oil and fats precipitate, and others do not precipitate. Some of the cil and fats are also corrosive. This may easily lead to a carry oe Impurities included dissolved ‘These impurities are oxygen, carbon dioxide and nitrogen, of which oxygen and carbon dioxide aro corrosive. -16-B25 Impurities easy to be dissolved (a) These impurities produce calcium biearbonate, magnesium bicarbonate and inerustation, and release carbon dioxide to produce calcium carbonate when heated. (b) Caleium chloride This produces incrustation, but becomes magnesium chloride when reacting with magnesium sulfate, which is extremely corrosive, (2) Caleium nitrate ‘This becomes corrosive when it is present in large amount. (@ Magnesium chloride ‘This produces incrustation, and extremely corrosive. (©) Magnesium sulphate This becomes extremely corrosive when it reacts with chlorides. (® Magnesium nitrate This produces incrustation, and is corrosive. (g)_ Sodium chloride This contributes to carry-over when it is present in large smount. Impurities difficult to be dissolved (a) Calcium carbonate This produces soft inerustation and mud. (b) Calcium sulphate ‘This produces hard incrustation, and inerustation heat, conduction, (2) Magnesium earbonate This produces inerustation, and causes the foaming of the boiler water. (@ Silicie acid This reacts with caleium, sodium and magnesium in a complicated ways to produce hard or soft inerustation, Either of these things is extremely poor in that conduction. (@) Salt of sluminum and iron Alumina, iron carbonate and secondary iron hydroxide float, and become muddy, causing foaming and carry-over, Soft. water and hard water To sum up the above description, it is found that bicarbonates such as calcium carbonate and magnesium tend to be dissolved in water. However, these bicarbonates release carbon dioxide to produce carbonates when the temperature of the boiler water is as high as 150 degrees centigrade (boiler pressure 0.4MPa). ‘These substances precipitate to the bottom as soft incrustation as the temperature of the boiler water rises. When more than a specified amount of these biearbonates is included in the water, it is called "hard water". This water has detergent less foamed when used for washing, but is separated and precipitates an incrustation when heated. It is called "temporary hard water", The water; which has lost a specified amount of hardness, is called "soft water -17-¢: & ‘e bb eo ‘As described so far, when the water sent to the boiler is heated, each of the impurities is deposited on the heating surface as inerustation, where the hardness of such inerustation differs according to the degree and place of heating. The hard incrustation such as sulphates is deposited on the flue and water tube, the sections exposed directly to fire, while bicarbonates become carbonates, and then the soft incrustation precipitating on the bottom of the boiler. oiler Proper Corroded by Boiler Water Direct cause(s) for corrosion Corrosion ocours in the section where water is evaporated most radically, such as flue, top of combustion chamber and the water tube exposed to combustion chamber, while some corrosion may oecur in section where water moves less frequently. Generally, when such corrosion develops as a chemiral reaction, such reaction becomes faster as the metabolism of the impurity is more radical. If however, a down wash is so strong as to allow less time for chemical reaction, less corrosion occurs, Some the causes for corrosion are indirect ones such as negligence in blow-off, incomplete cleaning of the inside, insufficient. cireulation of boiler water and overload applied. The direct causes, which are brought about by such indirect causes, are as follows in most cases’ Of course, it is often seen that more than one of the following causes contribute to corrosion. Reaction by gases included in boiler water Oxygen oxidizes iron by itself in water or high temperatures, and contributes to the recurrence of corrosion, In most cases, the oxygen contained in the water provides a good chanee for pittings, such as occurring in parts of the steam chamber where water moves less often, the water line of the boiler drum and pipes, the water tube and the economizer. Carbon dioxide produces carbonic acid when dissolved in water, and this reacts with iron to produce iron carbonate, The iron carbonate then reacts with oxygen to produce secondary iron oxide, Since this reaction involves a process where carbon dioxide is Reed, such carbon dioxide repeats another eycle of corrosion This kind of corrosion ends in round pittings as large as fingertip, rusted bluish black or reddish black. Corrosion by acids Apart from found pittings, the corrosion of wider areas is caused by the acids separated in the boiler water, and fatty acids separated from animaliplant tissues in the boiler water. Corrosion caused by salts Magnesium chloride corrodes the boiler proper most radically. This occurs because it is separated to produce hydrochloric acid in the boiler water. This does not end in pittings -18-3. 36 but ends in fish scale shape rust spreading wider, which occurs more often in parts exposed to strong heat, where air bubbles are hard to be freed, Not only magnesium but also the salts in it are all corrosive, while the salts in calcium are corrosive when they are present in large amount. Corrosion caused by local current Partial electrolytic corrosion is caused by the discharge current produced by local potential difference generated in parts processed, in impurities included in the materials, in parts with inerustation deposited, in parts where the density of the boiler water is different from each other, in parts where strong circulation occurs in the boiler water, or in different kinds of metals, ote. Comosion eased by overheated steam If the steam is in touch with the stesl surface heated from outside, the steam is separated into hydrogen and oxygen when the temperature of the steal surface reaches 400 degrees centigrade or higher. This oxygen corrodes the steel section, 34 Boiler Seale, Mud, Drift, Condensed Boiler Water 3. Pa AL How boiler scale and mud are produces In the wider sense of the word, boiler scale, mud and drift are all called "inerustation" Usually, any one of them deposited on the boiler surface, which cannot be removed by washing, is called boiler seale (seale). In the case of cylindrical boiler, the water inside the boiler is all evaporated when it is operated for about eight hours, while in the ease of water tube boiler containing less water, the water is replaces 4 to 5 times per day. In this, impurities are accumulated several times as much as each preceding day. These residual impurities are deposited as boiler seale, precipitated to the bottom as mud, or floated under or on the water surface as drifts, Result differs for each quality of the impurity, or the place where it is produced, As the boiler water is more condensed, dissolved impurities start to be separated in part(s) of the boiler water when over-saturated. In such case, the separated substances get mixed with those impurities remaining undissolved, where some of them, heavy in weight, will sink to the bottom less heated. This is "mud" Negligence in exhausting precipitated substances or a sudden removal of high- temperature water will allow this mud to remain deposited as boiler scale. If the scale accumulated on the smoke tube or water tube is removed for some reason, and if it precipitates down to the bottom of the boiler, it becomes mud. And if this kind of mud is crystallized again, and deposited, it may become a very hard substance. How heat conduetion is affected by boiler seale, mud, eondensed water Since boiler seale and mud conduct no heat, and air bubbles are produced less often in condensed boiler water, the tube plate or tube may he overheated, When the boiler water 219.is condensed, priming and foaming described in CHAPTER 2, Paragraph 2.1 are more likely to happen. 3.5 Limit Values for Feed Water and Boiler Water To minimize the effects to the boiler caused by impurities in the boiler water, these impurities should be reduced as far as possible, especially, in a boiler using high temperature and high pressure. Allowable limit values are specified for the feed water and boiler water of each type, and applications of the boiler. These are the limit values. They are merely a reference, not an absolute standard. Under each condition, these values can be raised / lowered according to the good sense of the controller, Internal checkup shall be earried out as often as the chance is given, so that the quality of the water may be controlled properly, and the usage may be optimized 3.6 Water Control and Water Treatment 3.6.1 _Ttems, and frequency of periodical control (a) Blow-off of boiler water Every day (b) Blow-off of the piping of low level FO cut off device Every 2 days () Quality analysis of water feed and boiler water Every 2 days (@) Boiler water treatment (boiler compounds and oxygen scavenger) 3.6.2 How to blow off (a) Blow off the boiler water a. Carry out a blow-offin low load. Supply water to H.W.L, before blowing off : as Carry out a surface blow-off up to NW.L. Supply water to H.W.L. again Carry out a bottom blow-off. Carry out this water treatment in, good communication with the water treatment company, based upon the quality analysis of feed water and boiler water. Carry out a blow-off efficiently by openinglelosing the blow-off valve occasionally. ig. The blow-off of about 150 to 200 mm in water level gauge is appropriate, h. In a blow-off, pay attention to keep the water level from falling below the critical level. (b) Blow-off of low water level F.0. cut aff dovieo a. Carry out a blow-off in low load. b. Keep the valve @ closed, and the valves @ and @ opened, and then carry out the =20-a. blow-off in the water side.(approx. 10minutes) Keep the valve @ closed, and the valve @ and @ opened, and then carry out the blow-off in the steam side.(approx 1munutes) Keep the valve @ closed, and the valve D and @ opened, and make sure the water level appears soon. (Make sure the contact is "ON"TOFF", as shown in Internal Wiring Diagram of Burner Control Panel.) 2.3.6.8 Control standard valves of boiler water (a) MVW type auxiliary boiler ‘The standard values of MVW type auxiliary boiler are as follows. When you apply the ranges shown in the standard, you can get the best standard values depending on the structures and operation method of this boiler. Consult with your water treatment company about them. Maximum Operating Pressure(MPa) Lmax Over 1 up to and inel.2 Kind of make-up water Distilled water* + Condensate Distilled water* + Condensate pH(at25°C) 8.0t09.2 8.01092 Hardness(mgCaCOsf) Bmax. Bmax Fats and oils(mgf) Keep low Keep low reed | Dissolved oxygen(mgON) Keep low Keep low Total iron(mgFef) O.max O.Amax Total copper (mgCul) : : Hydrazine(mgNsHul) : : Treatment method Alkali treatment | Alkali treatment pH(at25°0) 10.5 to 11.5 108to 18 Electric conductivity(us/em)(at 25°C) 1000max. 800max, Pealkalinity(mgCaCOsf) 100 to 180 100 to 150 Boller | Meatkalinity(mgCaCOu) 200 to 800 200 to 300 Chloride(imgC1"/1) 50max. Lomax Phosphate ion(mgPO.") 200 40 10t030 Silica(imgS102") 50max. 20max. Hydrazine(mgNsHu) 0.1008 0.1003 *Distilled water moans that distilled water is made with a distiller (Salinity 1Oppm not over) 22+(6) MESC or MVS type auxiliary boiler The standard values of MKS, MYSC, MKS and MVS type auxiliary boiler are as follows. When you apply the ranges shown in the standard, you can get the best standard values depending on the structures and operation method of this boiler. Consult with your water treatment company about them. Maximum Operating Pressure(MPa) 1 max a ie Pa pHlat25°0) 7009.2 8.01092 Hardness(mgCaCOsf) Bmax. Bmax Pats and oils(mgf) Keep low Keep low Feed "| Dissolved oxygen(mg0f) Keep low Keep low Total iron(mgFeM) 0.3max 0.3max. Total copper (mgCul) : Hydrazine(mgNsHu)) - : Treatment method Alkali treatment | Alkali treatment pH(at25'0) 11.0t0 11.8 105to11. Electric conductivity(ys/em)(at 25°C) 2000max, 1000max. Pralkalinity(mgCaCOsf) 100 to 180 100 to 150 Boller | Mtalkstinity(mgCaCOaM) 200 to 800 200 to 800 Chloride(mgCl7/1) 100max, 50max. Phosphate ion(mgPO.") 20 to 100 20 to 40 Silica(mgS1O:-A) 200max. 50max. HydrazinolmgNeHsM) 0.1008 0.10.3 *1 In the case of making-up after mixing with 5 to 10 pereent of raw water. *2 Distilled water means that distilled water is made with a distiller, -B-3.6.4 Others (a) Raise the temperature of the cascade tank (feed water temperature) to decrease dissolved oxygen. Water Dissolved oxygen temperature(C) | quantity (ppm) 10 10.92 20 8.84 80 7.68 40 6.59 50 BOT 60 4.76 70 8.89 80 2.89 90 1.65 100 0.00 (b) Use oxygen scavenger and control hydrazine Naka (Check for sludge on the water side of the boiler regularly, and use the agent which dissolves removes scale, if necessary.ALSeptember ’98 Instruction Manual for SL & SJ Series Safety Valves SL TYPE (SL100~SL300) SJ TYPE (SJ100~SJ300) ~— Fukui Seisakusho Co., Ltd.— 6, -chome, Shodai-Tojika, Hirakata Osaka /SAPANFukui Seisakusho Co, Lid, PRECAUTIONS ON SAFE OPERATION DO NOP FAIL TO READ THROUGH THE FOLLOWING PRECAUTIONS PRIOR TO USING SAPETY VALVE, AS IT IS ARRANGED TO ENSURE SAFE OPERATION OF ‘THE EQUIPMENT. FUKUI SEISAKUSHO CO,, LD. is a professional manufacturor of safety valves, and has provided customers with many safety valves, ‘The instruction manual describes the warning and safety precautions at its beginning, 80 that the eafoty valves can be used in safe and under reliable conditions, I these warnings and precautions are fully read prior to handling, repair or maintenance, it will be possible to minimizo any unstable conditions which may bo causod due to accident, incorrect handling or unsafe operation. ‘It is absolutely impossible for FUKUI to assure/predict all possible dangers or risks which may occur at the customer, user or maintenance/repair company, and therefore to provide thom with advise. When performing maintenance, repair or operation, using any other method or tool, which is not covered in the manual, it is necessary to fully acknowledge, that the safety of the operator himself or the salety valve may be compromised. Since high-pressure/high temperature fluid is used for testing, or during installation and/or prior to removal of safoty valve, it is nocossary to put on the protective glasses, carplugs, safety glovos, otc. Since the work environment for FUKUI's product, including danger which may be present. during euch work may be extremely diversified, it is not possible for FUKUI to predict the provable injury or damage. It is to be acknowledged that the warning, precautions, etc, are recommendations only for a safoty procedure and aro provided as an aid for eafoty.Fukui Seisakusho Co, Ltd, PREVENTIVE MEASURES FOR SAFETY DO NOT FAIL TO OBSERVE THE FOLLOWING PRECAUTIONS, TO ENSURE THE SAFETY DURING TEST, INSTALLATION, MAINTENANCE, BC. OF SAFETY VALVE, 1, Do not stand in front of safoty valve outlot whilo the safoty valvo is boing tosted or operating. 2, Be sure to put on earplugs while the safety valvo is boing tosted or operating, 8, Nover attempt. to look through the valve outlet carelessly during adjustment or valve seat leakage test, 4, Never install the safety valve horizontally, i.., the valve inlet centerline shall be vertical with baso of valve facing down, 5, Be sure to lead the drain piping to safe place from the safety valve should a connection be provided. 6, Secure a proper space at the circumference of safety valve, to allow the accessing in 360° , plus another space ut the uppor side, to allow the disassembling for test or maintenance, 7. When removing the safety valve from the equipment, make sure that the internal prossure is fully relieved, make it a rule to stand at a safe position, and put on the proper protective clothes, and safety glasces as the residual fluid may be splashed, onto your body. 8. Be sure to put on the tost: gag if provided always during ring adjustment. After testing, the gag must be removed, 9. For the safety valve provided with a lift Iever, attach euch valve with its lever located at-a proper position, s0 that the lever should not be pulled up accidentally. 10. Koop tho discharge port of the back pressure adjustment, needle pointed in the direction free of danger. If possible, itis dosirablo to connect the discharge port to the discharge pipe if it is not subject to excessive back pressure, Consult with FUKUI for suggestions and recommendations, Do not attzmpt (o execute excessively long piping for this discharge conneetion.Fukui Soisakusho Co, Lid, NOTES TO USERS 1, Storage and Handling 1.1 For Handling 12 For Storage ~ 2, Installation ~ 2.1 Safety Valve Installation 2.2 Peripheral Equipment Inlot Pipe ~ 2.8 Discharge Pipe 8, Hydrostatic Pressure ‘Testing of Vessel 4. Field Setting of Safety Valve ~ 4.1 Adjustment of Set Pressure: 4,2 Variation Rate of The Sot, Prossuro-~ 4.3 Tolorance of Set Prossure: 4.4 Adjustment of Blow Down: 4.5 Adjustment of 4.6 Standard Positions of Uppor and Lower Rings ~ 4,7 Trouble Shooting 4.8 Trouble Shooting for Other Difficult Problem: 4.9 Leaking of Safety Valve 5, Maintenance: 5.1 Removal ~ 6.2 Disassembly Procedure 6.3 Chocking af een lt ctl atta ier 5.6 Cleaning ~ 5.6 Roassembly. 6.7 Changing The Set Pressure 6. Sparo Parts 7, Maintenance ‘Tools and Supple 7.1 Lapping Blocks ~ 7.2 Lapping compounds~4. Fukui Seisakusho Co., Ltd, TO USERS NO! Bofore piping, designing, installing and/or adjusting the safety valve, you should first thoroughly read this manual, You may not understand all of the explanations the first time, However be sure to confirm the special notes heroin given, ‘This manual contains instructions for installation, adjustment and maintenance. PKI isa trademark of Fukui Seisakusho Co,, Ltd. Spare parts should be ordered from Fuleui, Address: 9% Floor, Yokohama-Jasuto 2gokan, 4-12, 2-chome, ‘Takashima, Nishi-ku, Yokohama, Kanagawa, 220-0011 Japan Phone? (046)441-4411 Fax? (045)441-0031 Specifications and materials are subject to change without any obligation on the part of the manufacturer,Fukui Seisakushio Co,, Lid. SL(GL100-S1.300) S4(S.1100-S.1800) 1, Storage and Handling Fukui safoty valve is, unlike its sturdy appearance, a highly sensitive device which is machined highly procisely on dimensional torelanees for its main parts, to keep high quality performance, And also, our safety valves are manufactured under our strict quality control due to stable functional performance and perfect sealing effect, and thon they are delivered from our shop after they passed our severe porformanes tect in accordance with our tost/inspoction standards. Take care of the following necessary items for storage and handling the safety valve, Moreover, please refer to specified rules (both mandatory and nonmandatory) in ‘tho JIS B 8210, API RP 620, ASME See | PG71, ASME SeeVil Appondix M, ote. Li For Handling (1) Don't perform rough unpacking, rough handling or sharp impact, if not so, the main parts of safety valve are damaged or subjected to shock, the centering will be out of alignment, resulting in unsatisfactory operation and seat loakago, @ When unpacked safety valves (open type) are transfered to the site, special care should be taken not to hook the part of which function and adjustments could be interfered with (.e. lifting lover, inside of york, ote.,) by uso of a rope, a hook or the like because they are subjected to malfunction. Never rope or hook the spring to lift. 12. For Storage (D Since safety vulves are, in many cases, delivered at several months prior to installation, the protective plates should never be removed just before the safety valves are installed on the site or perfomed the acceptance test, and they should be stored in the clean room to be free of dirts and low humidity condition. In the eases there are very long period before the safety valves are installed on the equipment after acceptance test, reinstall the protective plates on both inlet and outlet flanges of the safety valves, and then etore thom as above mentioned. @ Safety valves should not be piled up along with other products and should always be kept with the inlet, down,Fukui Seisakusho Co,, Ltd, 2, Installation 2.1 Safoty Valve Installation (1) Prior to installation of safety valves, a visual inspection should be carefully carried out, and the protective plate of inlet and outlet, the temporary attachments of inner portions of nozzle seat and outlet of valves (so that the inlet and outlet portions of the valves may contain bags of desiccant) and others ete,, are all removed, @) If foreign materials are in the internal of the nozzle seat, that should be removed by using a cloth or blown away by compressed air, Accumulation of foreign materials in safety valve inlet ports will be earried across the seat Gc. between dise and nozzle seat) while the valve is in operation and is frequently the cause of seat leakage. (3) A safoty valve should bo diroctly installed on the inlet pipe in the vertical position only. Othorwiee, if the conter axis of the moving parts is put out of alignment, which will affect the valve performance, Normal tolerance on vertical installation ie 1". @) Whon a flanged valve is installed, ensure that a gasket size perfectly matches the flange size, not to reduce the valve inlet and outlet port area, Also, the flange bolts must be fastened eavenly. 2.2, Peripheral Equipment of Inlet Piping (2) dust before installing a safety valve, the protective fitting on inlet and outlet shall be removed, And also, particularly in case of a newly installed boiler or vessel, there are many possibilities of spatter, slag produced at the time of welding, dust, rust and other foreign matters being present inside, therefore such boiler or equipment including pipe line should be cleaned as thoroughly as possible boforo the safety valve is installed. @) Inlet pipings on boiler and or vessel to be fitted with a safety valve must be made as short in length as possible, and then its inlet pipe entrance (diameter is D) must be rounded to a radius as large as possible (at least 1/4 D) and its inner diameter must be larger than inlet size of safety valve, the pressure loss of safety valve's upstream should not-be exceeded 2% of set pressure.@ o @ 2.3 @ @ @) Fukui Seisakusho Co, Ltd, Safety valves should be installed at least eight and more pipe diametors down EEE go Be oon stream from any bend or any se secon itt regulator valve in a pipe line, ‘The space for maintenance working in Fig.l must be kept as sufficient as possible to work for adjusting and/or maintenance of safety valves. For 4 inches and larger safety valve, it facilitate to provided a hanger hook at upper of it, for working, installing, removing and ‘Fig. Example of Good Installation disassembling a salety valve and minimizing the risk of porsonal injury. Discharge Pipe ‘The size of the discharge piping should nover be loss than the valve outlet size, and ite pipe line while having large curved section, should be led to out door, and then the arrangement should also be as short a possible, In case where discharge piping is longer inevitably, use a straight pipe as possible and increase its nominal diameter by V/2 to 1 inch for every 5 meter of pipe length from standard position, ‘The distance from the center of safety valve to the contor of discharge pipe shall be limited to a valve leas than or equal to 4(four) outuide diameter of discharge elbow. Where more than one discharge pipe are roquired to be connected to common main ling, the converging angle should be kept at 46° or less and the area of the main line not be less than the combined area of tho discharge pipes.Fukui Seisakusho Co, Ltd, (@) An exclusive expansion joint for the dischargo line should be installed go that it, will not impose undue sires or bad effect on the safety valve when considering thermal expansion of a boiler, a vessel or a discharge pipe, And then, the discharge piping to insert to the drip pan of expansion joint should be anchored to support the building structure as not to press the drip pan, (©) For safety valve in the steam line, due to discharge drain water which is condensed during blow off, ample provision for drain shal] be made in the valve body or in its outlet piping and this drain should bo piped to a aafe discharge area, And also provide a drain pipe for the drip pan of expantion joint. 3, Hydrostatic Pressure Testing of Vessel FEI steam safoty valves employ a disc structure of a feather lip type for low and medium pressure services, and of a thermal lip type for high pressure! high temperature services, respectively. In addition, the valve inlet is of a flanged type for low and medium pressure services, and of a welded type for high pressure! high temperature services, Perform hydraulic pressure testing on the pressure vessel (boiler) with these valves mounted, in accordance with the following procedure. (D. For flanged type safety valves Conduct hydrostatic pressure testing on the vessel with a blind plate provided between the valve bottom and the nozzle stub, (Note: For safety valves equipped with a hydrostatic prossure test plug before delivery, observe Step (2) helow) @ For welded type safoty valves Gee the document "Handling the hydrostatic CAUTION | pressure test plug” attached hereto.) Cau ie anor sea sae To Safety valvos of this type are delivered | Seerhg more with a hydrostatic pressure test plug | Hake yuk la Fr tyesatic gy built in, and a caution plate attached as rele ig, hetture tags 0 oT REMOVE Tes TAG Luca safety valves for low pressure service), FUKUI SEISAKUSHO CO,LTD, shown in Mig, 2.) (excluding some For details, see the approved drawing@), ete. ¥ig2Q) Tag Plato8) Fukui Seisakusho Co,, Ltd. Upon completion of the pressure test, keop this test plug with care in the specified accessories box, for reuse at the time of poriodic inepoction. When conducting a pressure test at a pressure lower than the valve set pressure, it may be carried out using a test gag alone without using this test plug. On the other hand, bowever, to perform a teet at a pressure above the set pressure, be sure to use the test plug. For safety valves delivered with a test plug attached, it is pro-loaded and therefore tightening the test gag slightly is good enough. Furthermoro, whon tooting safoty valvos for eot prossure adjustmont purposes, tako caro not to hook the test gag bofore a boiler is ignited (namely, when the Woiler is cold). If the spindle is not in a state of boing freely expandable in accordance with changes in temperature, it may be caused to bend or other intornal parte damagod, Handling the test gag ‘This test gag is used to prevent non-test valves from operating when testing ia carried out on a specific aufoty valvo for sot prossure adjustments, ‘The use of this gag is similar to that-used in a hydrostatic pressure test, Use the test gag as instructed below. When raising the pressure When the prossure has reached about 80% of the valve set pressure, tighten PLUG the test gag shown in Tig. 2@, and further tighten it in gradual degrees as the pressure increases, At this time, tuke cure that excess tightening may bend the spindle or cause damage to the nozzle seat or other problems, Ifa seat leak should occur due insufficient tightening of the test gag, Fig.2Q) Test Gag and Plug then temporarily decrease the pressure to the point where the leak stops, and rotighten the gag. Be sure to observe this procedure because failing to do so makes it difficult to stop the leak, as well as leads possibly to damaging the nozzle seat.Fukui Seisakusho Co,, Ltd. When lowering the pressure In eontrast with tho above caso of raising the prescure, loosen the test gag when the pressure has decreased to about 80% of the set-pressure. When the hydrostai the hydrostatic pressure test plug accordingly, pressure has been completed, remove the test gag and 4, Field Setting of Safety Valves ‘Tho field sotting of safety valve is dangerous work, it is very important to pay due attention to provent a risk of personal injury or a hazard, Adjustment of all safety valves manufactured by us is performed by ourselves at our works, but where the valves aro adjusted by yourselves at the field, any adjustment may be necessary for blocking it. Make adjustments of safety valves in the following manner, When adjusting a safety valve, first lowor the procure in the oquipmont, (ie, boilor and or pressure vossle) at 85% or less of the set. pressure of a safety valve to prevent hazard, and make necessary adjustments on each adjusting part of a safety valve. In caee where two or three safoty valves are installed on equipment, fasten the test, gage of all valves othor than a blocking and adjusting valve at-70 to 80% of the sot pressure, (The test gags are fastened lightly using fingers to prevent bending of the valvo spindle.) For the order, the test gag of lower sot pressure valves is fastened in advance usually, Furthermore, perform hand-blowing of each safety valve at about 90% of the sot pressure before allowing the initial popping actipn to take place, When they have passed some months after the safety valves were installed on the equipments, that are considered that forein matters enter in that and adhere to main parts, Therefore that ave recommend that the safety valves are disassembled and main parts are maintain at just before the field setting, This procedure shall be refered to Item 4.9.Fukui Seisakusho Co, Ltd, 4.1 Adjustment of the Set Pressure All of the safety valves have been adjustod accurately by us at our works with steam pressure 60 that there will be no need of further adjustments, In case that further adjustment is required, remove and adjust in the steps as followings, ‘Tablo~1 Intended State of Operation Adjusting Method ‘Turn the adjusting screw clockwise (When viewed ‘To raise the set pressure | fom above) and tighton it up ‘Turn the adjusting screw counterclockwise to ‘To lower the set pressure | | loosen it. ‘Fasten the lock nut each timo after the sot: prossure is adjusted, 4.2, Variation Rate of The Set Pressure In the following table the variations in percent per one turn of the adjusting screw are shown, ‘Tablo~2 SL Type Orifice Letter u/s |/K/LIMyN]PlQlR Variation (36) Bpluj}s}7}e]e6}5}a}ea ‘Table~3_ SJ Typo Orifico Lotter | F2 | G2 | H2| 32} Li | M | Na| P2 | Q2] Qa] R Variation (6) | 22 fis{}u}ol7folslsefa|a4]s or example) ‘type SL"Type Siva eer ADISTING SCREW. BR, ie Seeder ADISCREW LOCK HUTS. [Answer 7 Variation in percent for Orifice Letter YOKE. = Tax Variation per one turn: kf SPRING 8 ky Hem? GX 260.16 ke £/ mG E FigFukui Seisakusho Co,, Ltd, 4.3 Tolerance of Set Pressure ‘Table—4 unit!MPa (kg f/m?) Sot prossure ‘Tolerance 0,6(6) or less £0,014(40,14) above 0.5(5), below 2.323) £ 18% of set pressure} above 2,823), below 7(70) £0.07(£0.7) above 7(10) + (1% of set prossure} (Note) Above mentioned table is based on table 1 of Item 4, JIS B 8210 1994, Provided that where it is not allowed to exceed the set pressure, the tolerance of plus(+) side can be added to the minus(—-) side, 4A Adjustment of Blow Down (1) Adjustment by upper ring Because the closing pressure has relation with the capacity and resistance in the piping, it is difficult to cot it in the test stand at our shop 90 that it will accurately fit the situation in the field though all valvos are adjusted on the our test stand and delivered to user. For this reason, it is common practice to adjust the closing pressure of a safety valve of a boiler locally aftor tho valvo is installed on tho boilers. ‘The main adjusting devico used for adjustment of the closing pressure is the ‘upper ring provided at the bottom part of the guide. ‘This upper ring imparts a lifting force to dise after the disc has been popped up. To make the adjustment, fivet remove the lock bolt provided at the side wall of the valve body, through this screw hole, insert the adjusting rod as shown in Fig.6 and or rod like screw-driver and turn the teoth provided along the external circumference of the upper ring by using it, whore upon the upper ring will be moved vertically, ‘Table—5 Tntonded state of operation ‘Method of adjutment Peoping through the serew hole, rotate the upper xing with the adjust, Rod to the right by 0.5 turn to move it upward. Or throttle the opening area of the back pressure adjust needle, "Tp raise the closing pressure Peeping through the screw hole, rotate the upper ring with the adjust, Rod to the loft by 0.5 turn to move it down. Or enlarge the opening area of the back pressure adjust needle. ‘Tu lower the closing pressureFukui Seisakusho Co, Ltd, JIS B 8210-1994 mentioned above aleo specifies the closing pressure tolerances for steam-service safety valves as shown in the next table. The tolerance for closing pressure exceeding 0.3MPa(8 ke ff cm’) of steam-service safety valves that are to be used in once-through boilers, reheaters, piping, etc. can be determined as 10% of sot prossure or loss, Table—6 uunit:MPa (ke ff cm?) [Set pressure _ Bowiwn | <04@ <0.08 0.8) 0A aS <7% (4%) of blow-off pressure Notes: 1) Blowdown for stoam-service safety valvos shall bo differential pressure between blow-off pressure and closing pressure, 2) The value in parentheses can be used if agreed between the parties concerned, ‘The following table shows the limits of n mber of notches for upper ring vertical movement from the upper end surface of nozale seat, For the standard sot position of upper ring, please refer to the Item 4.6, ‘Table—7 Upper _ | Tower Upper lower SLitype | Limit of fLimitot | N%. | sa type | Limitot | Limitat | Novee Orifice | Adj, Adj. for 1 Orifice | Adj. Adj. for 1 Letter | Notch. Notch Tum Letter Notch Notch Tarn No. No, No. No. D- 39 8 26 F2 30, 90 30 G 30 90, 30, G2 66 148 37 H 55 148, 37 H2 82 164 AL 3 a2 | ia | at | a2 a5 | iso | 34 kK 85, 136 a4 La LUT 195 3a L ua 195 3g M 126 210 42 M 126 210 Az Na 175 250 50 N ‘147 210 42 P2 216 240 48 P 216 240 48 Q2 200 250 60 Q 297 270 64 Q3 297 270 54 R 434. 310 62 R 434 310 62 T 558 310 62 T 558 310 62 10Fukui Seisakusho Co,, Ltd, (2) Adjustment by Adjust Needle Safoty valves SL & SJ are equiped with an adjust needle shown in Fig.4 as an auxiliary for adjustmont of closing pressure. Back pressure on the back side of the dise is adjusted by varying the opening area of the adjust needle and this back pressure controls the closing pressure of the safety valves. ‘The closing pressure raised up by means of closing adjust noedle and lowored by moans Fig of opening, but neber totally closo. Moreover, it is recommended not to connect a pipe 1o a discharge opening of adjust needle, Even if connect to it, only elbow and a pipe (shooter than 50 cn), AQJUST NEEDLE \ ADJUST NEEDLE OPENING Adjust Needle Standard Position, Normal Dimensions of Serew ‘Threads for Adjust Needle Opening. ‘Table~8 ‘Adjust ‘Typos and Orifice Designation Sn Neue tircadl Standard sx100,200 | sLa00 | sy100,200 | svs00 | in Rp on Deke | DEF PF we 2 HS Ga G2,H2 ‘F2,62, 34” 86 KLM JK 2M | v2.32 Yr 45 LMN, NB,P2,Q2, ‘L1,M,N3, ya NRQR | BOR QaR | |paqzaan | bv i a + T 112” 55 uu4.5 Adjustment of Simmor If the simmer is too large, raise the lower ring one notch at a time, To accomplish this, cut the seal wire, remove the lock bolt, insert an adjusting rod into this bolt hole and turn the notehes on UPPER RING ~ the outer circumference of the lower ring to clock wise using the above rod. If go, the lower ring moves upward by screw. Refer to Fig.6. The following table shows tho limits of number of the adjusting notches for lower ring vertical movement from upward end surface of nozale seat, Yor the standard set position of lower ring, please refer to Item 4.6, LOWER RING Fukui Seisakusho Oo, Ltd, Fig. ‘Table-9 Upper _ | lower Upper SLtype | Limitof | Lanitof Root | S1'Type Limitof Pee Orifice | Adj. | Adj. | ROP? | Orifice | Adj, arate Lotter | Notch | Notch f°! letter | Notch [Noten | rt No, | No, No. _| No. p~r | 3 3 | a6 | Fe 3 23 | a8 G 3 2 | 2s | az 3 as | 33 u 3 si | aa | He 3 so | a0 a 3 30 | 90 | ae 3 | 3a] 38 K 3} 33 | a | 4 a | 42 L 4 a2 | a M 4 az fae M 4 a2 | 32 | NB 4 | ar | or N 4 36 | 36 | Pe 4 40 40 P 4 ao | 4 | @ 4 4 | 48 @ 5 sa | 52 | ae 6 2] 2 R 5 4s | 46 rR 5 4s | as . 5 43 | 46 ? 5 | «6 | 43Fukui Seisakusho Co,, Ltd, After the adjustments of the upper ring and the lower ring have been completed, arrange that the grooves on the tecth provided on both the upper and lowor rings are facing the center of the serew hole for the lock bolt, Afier insuring this correct positioning, roplace the lock bolt and tighten it, If the positions of tho grooves of both rings were not correct, the tip of the Jock bolt presses the ring with undue foree, thereby deteriorating the function of safoty valve. "LOCK BOLT ADJUSTING \ BooY RING ABT. 0.5inin Fig.6 Lock Bolt & Adjusting Ring Groove Positions 4.8 Standard Positions of Upper and Lower Rings ‘The standard positions of both upper and lower rings of types SL and SJ valves are shown the following table. Upper ring standard position; ‘The notches number of out-side cireumference of upper ring from upper end surface of nozzle seat Lower ring standard position; ‘The notches number of out-side cireumference of ‘Table~10 Type SL lower ring from contacting bottom surface of disc. Symbol(—) shows downward travelling, ‘Vable-11_‘lype SJ Orifice | Upper | Tower Orifice [Upper | Lower Letter Ring Ring Lotter | Ring | Ring p~H | —30 ~4 Fe~d2 | —30 -4 | JK ~40 - | Livre | -40 -6 L~P —50 -10 Qe~as | 50 ar ~60 —12 RT ~60 184.7 Trouble Shooting. Fukui Seisakusho Co,, Ltd. time —= ‘Table 12 Problem Phenomenon —_| Probable Cause | Corrective Action iidasad a Ifthe blowdown is too | large, raise the upper Lift ia obtained, Upper ring [ring 1 turn, han s position is tao eioeioena te low lifting force | Lf ube blowdown is a | is too large. slightly large, raise Hee oe the upper ring 0.5 by fine 0.5 tuen, Liftis obtained, Upper ring but it falls after ip eae position is too | Move the upper ring naar high, lifting — | 0.5 by 05 tum beans force is tno | downward, large, 7 time tiff Back Seer preseure Liftis attained | | on the dine is) Throttle the adjust but blowing, | ‘too small. aa does not stop . immediately Towor ring | Move the lower ring 1 dofore closing, positions too | j a pi jownward. uFukui Seisakusho Co, Ltd. Problem Phenomenon —_| Probable Cause | Corrective Action Liftean't be} jg, obtained and pesbiebesetenesta teas Upper ring —_| Move the uppor ring nat position is too | 0.5~1 turn downward, " high, Lift can't be ___ | Lfsafety valve doesn't ‘Sbtsined aod Lifting force is} close, perform hand Beedecaie too amall. blow. large, aoe | © | Upper ring cop Ty correct this, first Chattering soon | Position is 100 | Jowor tho prossure by after the high. hand blow, and then opening, ji ig | Move the upper ring. _ awn Taking ree is) 9.51 tuen downward. time. —~ ‘ft ‘The back iy prossure of dise | Tb correct this, first Liftis is too high, lower the prossure by satisfactory, but because the | hand blow, and then fluttor occurs discharge pipe | anove the back during opening. is too long pressure adjust needio and/or equipped | 0.5~1 turn upward, tine —— | With silencer. Wt hand blo¥ | phe pressure | Increase the blowdown | } } oss at the inlot_ | pressure, Decrease the pipe islarger | lift. Deciease the Hunting occurs than Blowdown. | pressure loss at the immediately afar apeuine inlot pipe. Move the ‘The back back pressure adjust pressure on the | needle 0,5~1 turn ine disc is too high. | upward. 16Fukui Seisakusho Co,, Ltd, 48 ‘Trouble Shooting for Other Diffcult Problems ‘Tablo~13 Problem Probable Cause Corrective Action ‘DLapping surfaces of dise | DPisassemble valve, lap surfaces and nozzle seat are of disc and nozale, if required damaged. replace disc by Instruction Manual. Ghischarge pipe is bound on | Olf necessary, remove undue ‘outlot, and valve ia stress on safety valve, imposed with undue stress, Valve leaking | PTB Partsofeafoty valve | @Disussemble valve, inspect and/or exhibits are mizaligned. contact area of disc and nozzle ‘miss popping seat, spring washors and aelon! spindle, adjusting serew, spindle straightncss, If necessary, repair or replaco them, @Dise reseat insufficiently, | @First, tighton lightly the valve spindle using test gag, and then hammer lightly the connecting aroa of yoko, Ifnecessary, disassomble valve and check die for proper rogoating, ‘Foreign materials are ‘Disassemble safely valve, and entrapped botweon guide | remove the foreign materials and dise holdex, using sand paper or the like, and No action, correct any smormal condition, Valve does not | @Upper ring position is too | @Adjust upper ring as outlined in open full lift high, tho manual, @Lower ving position is too | @Adjust lower ring as outlined in low. the manual. OForein materials. DVicaecemble safety valve, and Ratiaaidae remove foreign materials. close from full | liftor hang up, | @-0wer ring position is too | @Move the lower ring 1 noteh turn high. to downward per adjustment until problem is eliminated. ‘@Connecting pipe lines are | DInvestigate and eliminate eause. vibrating. Simmer @Lowar ring position is too low. @Aajust lower ring as outlined in the manual, 16Fukui Seisakusho Co,, Ltd. 4.9 Leaking of Safety Valve Whonever leaking is observed at Jes than normal operating prossure, find ont its cause as soon as possible and it must be removed, If as it is while long times, the damage of safety valve will become greater, (2) Leaking of valve seat and dise by foreign matter If foreign matter (.¢. welding bax, scale of pipe etc.) from equipment or piping system is caught between the nozzle seat and the disc, the leaking will be caused. However, such forcign matter may sometimes be blow off when the salety valve is opened again (or by means of handling the lifting lever as required), theroby leaking is stopped, If not so, leaking iv continue and the valve seating surface is badly damaged, then lap and repair the sisc and the seat is required, ® Reaction Force From Discharge Piping Leaking may be causod if the out let of safety valve and the discharge pipe are connected unevenly and then they impose undue stress on the out lot of safety valve. However this can be corrected by improving the installation of the discharge piping in early time. The acceptable load of safety valve is only a woight of the short discharge elbow iteclf and its flange. (8) Difference between Operating Pressure and Sat Pressure Alter safety valves are comfirmed to be free from leaking at the seat surface at 90% of set pressure in air tightness testing to be carried out at shop, they are delivered. In caso where operating pressure is higher than 90% of eet pressure, leaking may be caused. In this case, decrease operating pressure to equal and Jess than 90% of set pressure as soon as possible, 5. Maintenance Carry out the most proper service and repair to taking a knowledge of the condition of safety valve.eo that the safu, reliable operation of all valve products is kept. Proper maintenance manual are recommended as follows,Fukui Seisakusho Co, Ltd. 5.1 Removal Firstly, be cure that there is no pressure in the vossel and remove a safoty valve from vessel, next transfer it in a clean room and perform next procedure. In case where a safety valve is disassembled at near place of the veesel or boiler duo to wold with inlet pipe on the vessel and or difficulty of transportation of the valve, it is recommended to provide of small boxes and to put small parts of valve into these boxes. This manner is effective mothod of prevention of confusion with parts of other valves, loss and dropping, 5.2 Disassombly Procedure Q) Disassembly for Overhall ‘DUnlock or remove the seal, pull out the SLU S30) split pin ond the for lovar pin to remove SHI a tho fork lever. Then, loosen the sob sexe, cap Sees ‘and remove tho eap. SPROLE LOCK WoT — t Remove spindle lock mut, lifting washer UFTNG WASHER ~ st ‘and adjusting, serew. In this time, take FORK LevER = rovords or put matching marks on the TASNG LEVER PA ' adjusting sorew ta facilitate the reassembly. XSI LEVER — 7 @Romove the spring cover, Removo tho mut gps Lo — A Unt eonnet the yoko with th hod and ADUSTIG SékEW — Jif, up the block composed of the yoko, Ho cbas j ‘upper sping Washer, spring and lower vase Lt | spring washor. Bo earoful not to bond the Thee spindle in this lifting up process, Make sono. ———_| S matching marks in the ail lina on both YOKE 4 flange yoko and body, and Laon pull out the spas — 7 spinile, LOWER spas Wy @Pull out the disc from the guide, Pay WASHER i spocial attention this tima not to cause daunage to the dise and nozzle seat surface, Remove the upper and lowor lock bolt. ‘Then put tha matching marks on the ring or record the numbor ef notahes mavod, to facilitate tho reassesnbly, ADT NEEDLE — LT STOPPER hh ube EA How to Record Bree Lok ' Upper ring aT [eo] | Recon the nuuor of sates moved by st 40.06 —— ct turning the upper eng upwacts Ge [f= -— + atockvise view rom eutlt side of valve) Peek aes —— = | until it rozches tho dosd ond. Dis i , Lower ring wowace _— rr Record the number of notches moved by aS turning tho lowor xing upwards Ge, clockwise viewod from outlet side of valve) t-] —\__ until it reaches the dead end, Uv ee 7 eee Nozat Stal oor 1 Poll out upward the block consisting of the guide and upper and lowor ring, Thus the Fig? disassambling is completed, 18,Fukui Seisakusho Co,, Lid. (2) Disassembling Procedure for only Inner Parts of Valve Body Ge. partial disassembling of the disc and nozzle seat or replacement of disc etc.) © For checking or maintaining of the valve inner parts such as only lapping of disc and nozzle seat, or replacement of the disc only, if its disascombly is carried out in fullowing order, it can be done very easily without readjusting the set pressure, Procedure to remove cap is the same as above mentioned (1) At once, remove spindle nut and lifting washer from spindle, to insert a pipe or nut (these are a little largor dia, than spindle) in the space botweon lifting washer and upper end of adjusting screw. And then screw down spindle nut and lifting washer, © Make matching mark in axial lino oa both flange yoko and body and then remove the nuts that connect: yoke to the body, lift up the yoke block consist of sprin, spring washers and spindie slowly in perpendicular direction. In this ‘caso, take care not to bend spindle to hit the other. © Thereafter, follow (5) and (6) in Item 1. Dieassembly For Overall described above. 63 Checking Check all the parts disaseembled one by one, Particularly, the following items are important. (D Seating Surface of Disc and Nozzle Seat Ian inspection of the parts shows the valve seating surface to be badly damage, Dite or seratch, the lapping will be required. (2) Sliding Surface between Disc Holder and Guide © If damagos, dirt’, foreign matters and the like are appeared on the sliding surface between disc holder and guide, it is very important to remove them from these surfaces by using of fine sand paper. In this time, take care not to rub their coat surfaces with sand paper. And then should do checking if smoothly moving could be attained by moans of sliding the dise holder and guide after having repaired ® The Clearance between Disc: Holder and Guide Check if the clearance betweon the out side of the disc holder and the guide as shown Fig.8 is within the limit as describo bolow table. 19Fukui Seisakusho Oo, Ltd. Table-14 Out Dia. of Dine A= Bm = 60 0.5 ~ 0.80 50 < OD S100 0.20 ~ 0.88 100 < 0D S160 025 ~ 047 ~ 160 < OD S200 0.30 ~ 0.56 200 < 0D 040 ~ 0.76 \ cE oe on Fig8 SC FOLDER, (@) Checking Spindle Concontricity In order to transmit tho spring load to the dise without lateral bending, the spindle of the safety valve must be sizaight, Since the valve gpindle may be bent by rough handling or over gagging at the test, check the spindle for bend by the following manner, Checking the block on a latho as shown in Fig.9, to fix the end of the spindle, and support the other end with the tail stock conter, With this setting, rotate the spindle gently, and apply a dial gage at the center part of the spindle, and thon measure the deflection of the spindle. ‘The value of thie deflection to be 0.15 mm or smallor per is a allowable, If there is the deflection more than this, it must be repaired or replaced with spare. BLOCK f mans | GA Wei SSS care as 60 that a top of adj. ring lock bolt is inserted into the groove of adjusting rring out side, Please refer to Fig. 13. © And then, after adjusting for operation of Fig13 Adj. Ring Lock Bolt the safety valvo are finishod, install the cap and seal it, ABT. 0.5mm @) For Procedure without Disassembling the Upper Parts including Yoke, ‘To apply antiseize compound on the tip of spindle and taking caro so that it does not hit the other install them (ie, upper parts including yoke) on the valve body, After that, the reassembly should be done as same as procedure below Itom 6.6.()© above mentioned. By above described, the reassombly of safoty valve is finished at all, (@ If the matchmark have been disappeared and or the records of orignal position of adjusting ring have been lost, provisionally set and adjust by means of procedure diseribed below. © Measure and record the height from the nozzle seat to the upper edge surface of valve guide as shown in Fig.10, Dimmension B. 25Fukui Seisakusho Co,, Ltd. @ Determine the height from bottom line of upper adjusting ring to the upper edge surface of guide by the following formula, Refer to Fig.14, ASB+2 mn (equivalent to about 28 to 52 notches, doponding upon the valve sizes) And then provisionally reinstall the upper adjusting ring at this position and start the adjusting. @® Lower the top of lower adjusting by 0.4 m(equivalent to about 7 to 10 notches, depending upon the valve sizes)'from the upper level of the nozde seat to downward, And then make sure this height from tho top of lower adjusting ring to upper engaging surface is 0.4m larger than Dimension B when to measure the B value, ~ Ge PEE ADSI my Fig.14 5.7 Changing the set pressure If it becomes necessary to change the revised set pressure from the value specified on the nameplate, the spring must be replaced. Since epring has great influence on the performance of a safety valve, springs that fit for the revised sot pressure are designed, Therefore, any change in the set pressure, please contact with us (je, manufacturer) and then make sure the spring to be replaced is appropriate for revised pressure. In replacing spring, both upper and lower spring washer should be replaced simultaneously since they need to fit for the spring. It ig necessary to restamped on the nameplate or to replaced with new name plate,Fukui Seisakusho Co, Ltd. 6. Spare Parts As rogards the safety valve spare parts, it is necessary to store the proper quantities of the requested spare parts depending upon the used condition, In maintenance for safety valve, if enough quantities of spare parts are not stored and then it becomes necessary to repair or to replace the parts, it may be required ‘to shut down the operation of the equipment for a long time or to make expediently repaire, considorablo amount of loss may be happened. Usually, the spare parts are springs including upper and lower spring washer, discs and mozzles seat. It is recommended to siore the parts which may be corroded as spare parts at all times, Furthermore, although spring and dises as spare parts exactly fit in specified condition, those parts shall be not used for other than appropriate safety valves even if the size and the sot pressure is available, When ordering spare parts, please inform us (manufacturer) the part name, and scrial number size and set pressure which are stamped on the nameplate of safety valve required. 7. Maintenance Tools and Supplies ‘The following tools and supplies are required for proper maintenance of the safety valves, Thoso tools and supplies may be purchased separately from FUKUI SEISAKUSHO CO, LTD. 7.1 Lapping Blocks Lapping blocks fittod for size, shape of dise and nozzle seat, Refer to Fig.10 and Fig.12). 7.2 Lapping compounds @) Lapping compounds @600) Maxk:LP-1 #1200) Mark:LP-2 (#3000) Mark:LP-3 ‘Mark:LP-4 27Fukui Seisakusho Co, Ltd, EACH KID OF CONPCLAD FILLED IN THE BOTTLE OF POLYETELENE = LP LAPPEG COMPOUND KIT wen Fig.16 note: Lapping compound kit may be transported just as exsiting condition beeause a foamed poly-styrone resin material is fulled in this kit, 28.Instruction Book for Boller Water Supply Control System Item 1.Principle Drawing for Bolter Water Supply 1 Controt system 2.Adjustment for Each Equipment 3 3.Fi(ling Water Procedures for Differenciat 10 Pressure Transmitter 4.Cautions for Operating Procedures of Differenclal 13 Pressure Transmitter Prepared by:Tortolse Engineering Co.,Ltd at 700,Kite-Gowara,0az0 Masaki cho, !yogun Ehime Pret. JapanSy (tun Jomog) an apis 3d USIH 3D wo SeeaeeCnaLet saute eTeSEEG (204 1008) sosuepues 19401 D apis SSS SS © —*A v WayEKS yoIUog AVGGNS JsVOM 18110G 10} BUIMDIG SidloUIIa Tt(Principle for Water Level Measurement) Measurement method of boiler water level by differencicl pressure tronsmitter (Please refer to Principle Drawing) Is made difterencial Pressure between the water Pressure H In condensor and water pressure I In bolter.and water level is obtained by the comparison of above mentioned pressure. (Explanation for Principle Drawing) When boiler water level is Increased more than N.W.L,woter pressure | Is Increased and It 1s added to Seal Dlaphram at low pressure side (2) and then Increosed pressure Is compared with water level pressure H in condensor.Difference pressure Is converted to electric signal. This is principle. (Table of Water Level Output Signal) A mA B% Pressure Transmitter Output signal Differencial Output signat = 2 am NaW.L(Ona) +12 an | Boiler Woter Level Indicator y mn! Setter Woter bevet tnateoter x mm} 0 mm Y/2 nm Y mm Ronge for Boller Water Level Indicator Ym2.Adjustment Procedures for Each Equipment a,Differenciat Pressure Transmitter (Set up for basic data) (Zero adjustment) Externat Zera Adjustment, Adjustment Procedures (Set up for basic data) Set up of bosic dato for differencial pressure transmitter Is made when it Is delivered from our factory (it Is not necessary to change basic data) (Zero Adjustment) In order to execute Zero adjustmen @ Water level in boiler is set ot N.W.L. @ Alarm device for digital indication Is adjusted to "0" position by external zeroadjustment knob, (In case of zero-adjustment, turn the knob within about 45*with o slotted screwdriver.)b.Digital Indicator Adjuster (Set up for basic items) (Change of set up vatue for boiler water level) Adjustment of diaphram valve for boiler water supply.atarm for high ond low woter level cre set by digital indication adjuster (Please refer to final drawing for boiler set up value) Adjustment Procedures basic set up Items for digital indication adjuster are set when it ls detivered from our factory. (In case set up volue change is necessary,please obtain by Makers’s Instruction book) (Change of set up vatue foreach boller water level control) In case of set up value for eoch boiler water level control Is chenged, please reter to the fotlowing table. Digitat Indication Contents of boller Adjuster water Level controt Set up for SP alophram vatve ‘Set up for alarm for boiler evi water tevel nigh Set up for alarm for boiler Eve woter level Low Set up for boiler woter Ev3 ow(bunner 1s shut off)80621(96x96 size) @no.1 inetcator @woae Leo @no.2 indicator pissy oreon bet © @ : ®oisp coy ®serev key a Oe UP a> key PARA koy 7 @ Locder connecter fon) G @ent key @Boow & rey Qno.1 indicator stndiectes o PviProcess Varioble)end can alse Indicate tne contents of porometers.ete. @®no.2 indicotor :inéleates on sP(Set Polnt)and con oiso indieote the numerics of poroneters.ete. @noser ceo ‘Lights according to the operation of this Instrument. sP/ovr ‘Inéleates wnot 18 expressed In the No.2 Indicator. EVI to EV3 Lights when on event output Is turned on. OT Relay output(o0),Lignts when the reloy Is turned on,and goes out wnen the relay is turned off, Voltoge output(60).Flasnes according to output duty, Current output(5G).Lights normetty, ar :Floshes during auto tuning operation. Lights during overshoot suppression ‘earning. Green elt sLignts within tne ronge set in setup item c23, Flashes when the remote switch is turned on, @ sreen veit Lignts wnen o ditterence(deviation)betwoen PV(Process Vortableyond sP(Set polnt)is within @ predetermined renoe Floshes under the READY condition. @®o1sP key veet the gisploy to bosic indication stotus, Indicates 9 PV on the No.1 Indicotor and an SP on the No.2 Indicotor.Determines the contents of the No.2 Indicator. @srrv ey sehenges en SP(Set Peint)or 9 set votue of on event(optionat). @ PARA key sehenges Paraneters. @® ent key Det ines ¢ cnonged nuner ic. @©ur @ key snereases numeries. @ down Ce) key sdecreases nuneries. Qtooder connector:This connecter 1 used to connect tho Hondy Loeder(optinet). -5-chenging on SP (with single SP) To change an SP value of single SP,follow the operation procedure given below. loperation Procedure The Procedure for changing the SP trom 0 to 100 @-—_®-—_©-—_® To set to basic Is shown below. Indieation status JA pv votue ot thot tine Is Incicated. ise Press the C5 key ots JA Pv votue ot thot time 1s indicated. An SP volue,oUT oF c heoter current volue Is Ingieeted, To Indleote an se [sr is ineicetea. Press the GZ ker oot 2LL_[5lGk+— the set voiue of thot item floshes. To change the set votue = F chonse tne numeric, seo! ag] TG|a-— tne enonvea nuneriec using the GA) or CD key ure paetananey To define the chances numer fe FP ‘the CENT) key tore! {G|G— does not floes. =Floshing stops ang the ser valee ts gefisess To reset to bosic Indieetton stotus an pv ounerie 12 ise Indicoted. Press the key je" sateelnaastieti Indicoted. Note) With mult! SP (COB*1),SPO Is Indicated In the Nowt Indicotor.end its 0 flashes. In this cose.SP selection le done.Changing the Set Value of Event(optional) Wnen the event(alorm function) function (output at alorm position) can be changed. on ore k-HYs—>4 Is provided ot option,its set velue In this example, the event output Event set vatue (EV) than theevent set vatue.the event set value lower thon the event set velue(hysteresis).The procedure for changing the event set value Is shown below as on example Operation Procedure the event 2 from 70 to 80 The Procedure for changing the event 1 from Pv Is turned on,when the PV becomes higher Is turned oft wnen tne PV is 10 to 20,ané Is shown below as on exomple. To set to besic Indication status }e—A Pv volue ot thot time 13. Indteoted. our spe Press thee key cbr Jan sp votus-our or Value Is Indiested, @ to indicate the event — [ETP [fees 1s incicoted. Press the @ZD key sro) [Jil etasnes twee OUTo a H To chenge the set vetue [ETT Press the key or spo SS Cas tty 0883 LLJeIa kK Ftesnes. Tarihi oxenple, prose the C&) key to chonde 10 to 20 @ to aetine the chensee [ETT numeric Press the (Bil) key 882 LL ToT noes not ttash. @ To indieate the event 2 Cle Je—e2 15 indicated. ress the ° spoT [7a] osnes P the @ZD key ours TZ} Ftosnes. @© To change the set value Ele Press theG@) key or spo oe off JH Ftesnes. ih this exompte.press the G&D key to change 70 to 80 @ to derine tne cnonges numeric Ele so lesaenttsecittas Press tne key ote LLIEIG— oees not rtosn. 1 @ to reset to deste JA Pv oumerie is indication stetus indi ceted. ise spo An SP numerte ts Press tne => key otre eceeettTe change PID value The procecure for changing P=5.5 Is shown below, © To set to dasic Indication stotus J—A Pv volue st that time Is Indicated, ise spo Press the) key oure Je—an se vatue.cur or o neoter current value Is Indiccted. @ To indicate the parameter J— the item ossignes to the (CMA) key Is Indicated, ° Je—The set votue of thot Item Is Indiceted, Note) Repeat pressing the (PARA) key several times until the Press the GARE) key s ou @ to indicate (Proportional band) Pp JP Is indicated, ooo] [e]te— ne set voiue of thot @ To cnange tne set vatue B SH key Sater: Z GE ey Te Ep — vee not ttasn. Flosning stops ond the set value Is defined, © vo reset to beste Te eeneiiet baal LAA ev numeric ts indicates. ise ee Jan sp numeric 1s indicoted, Press theC_) keyevel Indicator(control room) Nome Plastic Volume tor Plate cover Indicator Span odjustment SS & Volume tor ZeroAdjustment Adjustment procedures for zero is as follow: 1.Water evel In boiler is set ot N.W.L. 2.Confirm that the digital Indication adjuster points out ot “Zero”. 3.Name plote for level indicator,plastic cover and indicator are Femoved,ond then water level indicator is set tor N.W.L.(Omm) by Zero Adjustment volume,3.FitLIng Water Method for differencial Pressure Transmitter Filling water method is varied depend upon boller condition, and adjustment is mode according to boiler condition, A.Fitling water Method after Boiler Water Level is Set UP a (2) (1) Toke out alr from difterenciat Pressure transmitter Blow plug (2) Toke out air from seal pot (Level Indicator Digital Indicetion Adjuster Operating Procedures 1.Water level in boiler is set at N.W.L. 2,Remove air take out valve for seal pot (2) 3.B.D.E & C are opened(At this time,water inside pipe Is increased to "b” Level 4,0pen plug for (1) and take out alr from ditferencial pressure transmitter,After that,plug Is closed. 5.A & D are closed.Water Is supplied from upper side of air take out (Water Is supplied until overflow condition at alr take out) 6.A Is opened (Water level becomes “a” position) 7.Instoll oir take out plug for seal pot (2) 8.DIgital Indication Adjuster Is set “O° by zero adjustment of differencial pressure transmitter. ~10-B.Water Supply Procedures after Boller Pressure Increase—1 Operating Procedures 1.Water tevel In boiler is set ot N.W.L, 2.0 & Bare closed.C.D & E are opened 3.Plug for "6" Is removed ond water Is supplied untit overflow condition at “G7 position.F1 & F2 and b cre loosened,and air is taken out trom pipe ond differencial pressure transmitter, (After confirmation of air taken out completely,FI,F2 and b are closed) 4.D Is closed. Install plug for "G7 -A & B are opened at some time G.After that, digital indication adjuster is set “0” by zero adjustment of differencial pressure transmitter. oC.Water Supply Procedures after Boiler Pressure Increase (Pressure Below 1k9/cm®)—2 Operating Procedures 1,Water level in boiler is set at N.W.L. 2.A 1s closed.8,C,D & & are opened 3.Air is taken out from Fi and F2 of differencial pressure transmitter (After confirmotion of air Is taken out completely and then Ft and F2 are closed) 4,Loosen plug for "G* ond water Inside pipe is flown reverse direction ond air is taken out until water overflow ot “G” Plug (pipe is knocked and alr is taken out completely) S.After air is taken out completely,plug for "6" Is closed and A is opened, G.After water temperature Inside pipe is stabilized,digital Indication adjuser Is set “0” by zero adjustment od differenclot pressure transmitter. 124.Cautions for Operating Procedures of Differenciat Pressure transmitter Water Level Indication Differencial pressure transmitter has generally some errors of output signal (water level indication)between time for completion. of adjustment and during normal operation time, The followings ore required time for stabilization of equipment and errors, o)Required time for water temperature of each pipe Line becomes same os ambient temperature b)Errors ore difference of specific water gravity in pipe line of water level indicator and ambient temperature when differencial pressure transmitter is adjusted. c)Required time for eascape of remained air volume In pipe tine It Is voried depend upon the above conditions. Therefore,after a few hours of normal operation for boiler, temperature Is stobilized.And then woter level indicator and ditferencial pressure transmitter is adjusted in order to obtain eccurate Indication,OM2-8113-0201 CV3000 Series r Control Valves Model : HLS,HTS,HPS,HLC,HSC,HAV User's Manual Yamatake CorporationCopyright, Notices and Trademarks Printed in Japan Copyright 1998 by Yamatake Corporation While this information is presented in good faith and believed to be acdurate, Yamatake Corporation disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as. may be stated in tis written agreement with and for its customer. In no event is Yamatake Corporation liable to anyone for any indirect, special or consequential damages, The information and specifications in this document are subject to change without notice.10. on TABLE OF CONTENTS GENERAL. LL Scope. 1.2 Major Components of Control Valves. 13° Structures. 14 Nameplate. INSTALLATION... 2.1 Maximum Lifting Loads: ofFyebots 2.2 Installing Valve in Process Pipe. 2.3 tems to be Checked After Installation and Before Starting Operation INSPECTION AND MAINTENANCE... DISASSEMBLY AND ASSEMBLY... 4.1 Detaching Actuator from Valve Body 4.2. Disassembly and Assembly of valve Body, 4.3. Disassembly and Assembly of Actuator. 44 Disassembly and Assembly of Model HAL Actuator «00 4.5 Disassembly and Assembly of Model HA2, HA3, or HA¢ Actuator. 4.6 Disassembly and Assembly of Model PSAG Actuator. ADJUSTMENT DIRECT/REVERSE ACTION TYPE CONVERSION AND SPRING RANGE CHANGE OF ACTUATOR 6.1 Dircet/Reverse Action Change. 62 Stroke and Range Spring Change. INSTRUCTIONS FOR TOP HANDWHEEL OF ACTUATOR...... 7.1 Model HAI Actuator .. a 7.2 Model HA2, HA3, or HAS Actuator... INSTRUCTIONS FOR SIDE HANDWHEEL OF ACTUATOR 8.1 Installation Procedure... 8.2 Operating Instructions .. 83 Disassembly and Assembly of Side Handwheel INSTRUCTIONS FOR BELLOWS SEALED TYPE OF CONTROL VALVES .......67 91 Structure. 9.2 Disassembly and Assembly TROUBLESHOOTING ....... RECOMMENDED SPARE PARTS.1. GENERAL 1,1 Seope This manual covers the instructions for the following Control Valves «Model HLS : Small-port single-seat control valves Model HLC : Small-port cage guide type single-single seat control valves Model HTS : Top-guide single-seat control valve Model HSC : Cage type single-seat control valve Model HPS : Top-guide high-pressure single-seat control valves Model HAV : Venturi throat type angle control valves For the valve positioners, refer the following operator's manuals. Model HLS Small-port single-seat control valves Model VPE 0M2-8310-0410 nematic valve positioner for small actuators Model HTP 0M2-8310-0200 Pneumatic valve positioner (Single Acting type) Model HEP 15, 16, 17 OM2-8313-0100 —_Electro-Pneumatic Valve Positioner (Single Acting Type) Model HEP 35,37 CM2-HEP350-2001 Eleciro-Pneumatic Valve Positioner (Single Acting Type) Model AVP300, 301 CM2-AVP300-2001 Smart valve positioner 1.2. Major Components of Control Valves Each control valve is comprised of two major components, namely, a valve body and an actuator. Various combinations of valve body and actuator are available to meet various type of uses with different valve sizes, pressure ratings, types of connections, types of materials, and actuator sizes (For details of specifications, refer to Specfication Sheets SS2-8113-0200, -0210, -0300, - 0310, -0400, and -2600.) 13. Structures The structures of typical CV3000 Series control valves are shown is Fig . 1-1 through 1-3. The valve body is connected to the bonnet with stud bolts and nuts. A gasket is (two gaskets are) provided at the connection section to seal against the internal fluid or to let the valve body make up a pressure vessel. The valve plug is supported by the guide ring and cage, and driven by the actuator. The actuator has multiple springs and a diaphragm, and converts the pneumatic control signal into a mechanical (positional) control signal with whick to position the valve plug,Fig. 1-1A. Small-Port Single Seat \9. 1-4B, model HLC Control Vaive, Model HLS. (Direct Action Type) > > Fig. 1-28. Top-Guided Single-Seat Control Valve, Model HTS Fig. 1-3A. Top-Guided High-Pressure Fig. 1-38, Venturi-Throat-Type ‘Single-Seat Control Valve, Angle Control Valve, Model HPS Model HAV1.4 Nameplate A nameplate as shown in Fig. 1-4 is posted on each control valve. The nameplate indicates the model number, valve size, pressure rating, trim material, date of manufacture and other major specifications of the control valve, Before installing the control valve, make sure that the specifications indicated on the nameplate conform with the conditions of use. The nameplate indicate also the product number (PROD.NO.) of the contro! valve. Please mention this number also when consulting your Yamatake Corporation agent for replacement of parts or other modification of the control valve. Fig. 1-4, Nameplatefer INSTALLATION 2.1 Maximum Lifting Loads of Eyebolts ‘The diaphragm case has a pair of lifting eyebolts. These eyebolts primarily are for lifting the actuator alone. When using the eyebolts for other purposes (such as lifting an actuator fixed 10 its valve body or other components), note that the allowable maximum lifting loads of the eyebolts are as shown in the following table. Table 2-1, Maximum Lifting Loads of Eyebolts ‘Actuator Model Allowable Maximum Lifting | Weight of No. Load of Eyebolts Actuator Alone HAI 160 kg ako | HA2D, HAZR, 160 kg 16kg HA3D, HABA, 160 kg 32kg HAAD, HAGA 220 kg akg Note: The eyebolts may be used to lt the actuator together with its valve body (cast globe valve) of up to pressure rating "Class 600." When doing this, be extremely careful so that no shock ‘oF other abnormal force Is applied to the actuator or the valve body. 2.2. Installing Valve in Process Pipe 23 (1) Before installing the valve in the process pipe, remove foreign matter (such as scales and welding chips) from both upstream and downstream sides of the process pipe. (2) Confirm that the direction of process fluid flow conforms with that of the arrowhead mark provided on the valve body. (3) Pay attention so that the pipe connection gaskets do not extrude into the process pipe inside. Be sure to use gaskets made of material which is suitable for the process fluid. The welding type of valve employ no gaskets. (4) Pay attention so that no excessively large stress is conveyed from the process pipe to the valve body. Uniformly tighten the bolts of the process pipe connection flanges. The high pressure type of valves have no flanges, since they are connected to the process by welding. (5) Before connecting the air pipes to the actuator and positioner, blow the pipes to clean them. (6) Do not install any heating or cooling provisions on the bonnet. Item to be Checked After Installation and Before Starting Operation (1) Check that there is no leak from air piping. (2) Check that the bolts and nuts of the diaphragm case are not loose. Standard tightening torques are as follows: (3) Tighten the packing flange nuts to prevent leak from the gland packing section. Standard tightening torques are as shown in Table 2-2, 4.Table 2-2. Tightening Torques of Packing Flange Nuts Valve Stem | Asbestos Yam | Metallic Filament Reinforced V teflon Diameter) Packing Asbestos Yarn Packing Packing (mm) — | (N-m {kgF-em)) (Nem {kgt-cm)) (Nem tkgFom}) 10 3(30} 7 (70) 118) 13 5 {50} 12120) 1(8} 16 8 (80) 18 (180) 1 (8) 20 10 (100) 25 (250) 1(8) 25 15 {150} 40 {400}, 18) 30 20 {200} 50 {500} 18) Note: The tightening torques mentioned in the abve are only to give you reference values. Note that tightening torques may vary depending on the type of packing ll NG FLANGE V PTFE PACKING cower aseestos ACK me Puc 5 1B (Swertearios uae SHEE iy V PTFE Packing Asbestos Yarn Packing Fig. 2-1. Gland Section (4) If the valve is provided with a lubricator as shown in Fig. 2-2, check whether the bonnet section has been lubricated or not. To do this, loosen the lubricator handwheel and turn the squeeze screw. If he squeeze screw turns lightly, and grease in the lubricating procedure mentioned below. (If the squeeze screw turns heavily, this means that grease has been applied.)‘Squeeze screw — FC% Lubricator handwheel——-) Fig. 2-2. Lubricator (Class 600 or under) Fig. 2-3. Lubricator for High Pressure Valve (Class 900 or higher) Lubricating Procedure (a) Prepare grease of the type indicated on the nameplate. (b) Tightly close the lubricator handwheel. (©) Remove the squeeze screw, apply grease, and set the squeeze screw. (@) Loosen the lubricator handwheel and drive grease by turning the squeeze screw. (©) Repeat the procedure of (b), (c) and (4) until tuming of the squeeze screw becomes heavier. Tightly close lubricator handwheel. (5) Pressurizing the valve, check that there is no leak from the gasket sections for connection to the valve body and process pipe, If leak is found, tighten the nuts. (Especially when the process fluid temperature is 400°C or higher, tighten the nuts again after raising temperature of the valve in order that it may serve for a longer period without requiring immediate maintenace service.) Standard tightening torques are shown in Tables 4-4, 4-5 of Section 4. (©) When raising temperature of a valve which is used for high temperature service, raise temperature gradually (standard rate is 100°C per hour) and do not operate the valve when its temperature is being raised3. INSPECTION AND MAINTENANCE Inspect and service the actuator as follows: (1) Tightening the gland: ‘Tighten the gland once in every 6 months or thereabout. The tightening procedure is as given in Section 2-3-3). (2) Lubricating the gland: Lubricate the gland once in every 6 months or thereabout. The lubricating proce- dure is as given in Section 2-3-(4). (3) Cheek for hunting of valve position: Refer to Section 10 "TROUBLESHOOTING." (4) Check for abnormal noise and vibration: Refer to Section 10 "TROUBLESHOOTING."4, DISASSEMBLY AND ASSEMBLY This section covers the disassembly and assembly procedures of the actuator for its overhaul or modification, 4.1 Detaching Actuator from Valve Body (Refer to Fig. 4-5.) (2) Apply to the actuator an air pressure so that the valve position pointer is at a point of 10% - 20% above the fully closed point. (2) Loosen the clamping-bolis of the stem connector, remove the stem connector, and detach the actuator stem from the valve stem. (3) Remove the clamping-nut of the yoke. (4) Raise the actuator to detach it from the valve body. Precautions: For detaching the actuator from the valve body which is kept installed in the process pipe, be sure to shut down the process for and release the process pressure before detaching the actuator. 4.2 Disassembly and Assembly of Valve Body To disassemble or assemble the valve body, refer to Fig. 4-1 through 4.4 and proceed as described below. (For handling of the bellows sealed type (optional type) of valves, sce Section 9.) Disassembly Procedure (1) Loosen the hex nits of the packing flange. (2) Remove the hex nuts (1) of the bonnet (extension bonnet). (3) Raise and detach the bonnet from the valve body. Precautions: If the valve plug comes out together with the bonnet, remove the plug from the bonnet by rotating the plug. When doing this, exercise care not to damage the valve stem. (4) Model HTS, HPS and HAV Valve For Model HTS and HPS valve, remove the guide ring. The seat ring is fixed to the valve body by threading, To remove the seat ring, special tools (optional) are necessary. (Model HLS, HLC valves have no guide ring and in its stead the valve has a guide bushing pressed in the bonnet.) Inspection Inspect the disassembled parts for damage. If any damage is found, replace the parts. (When ordering parts, mention also the Prod. No, of the valve which is indicated on the nameplate.) (1) Do not re-use the removed gland packing. Use fresh packing when assembling the valve.(2) Check that the seating surfaces of plug and seat ring are not damaged. (3) Check that the gasket-contacting surfaces of valve body, bonnet and guide ring are not damaged. Do not re-use the removed gasket. Use fresh gasket when assembling the valve, (4) Check that the plug guide section, the stem, and the internal guiding sections of guide bushing are not damaged. Assem| ly Procedure © Model HLS, HLC (1). Securely fix the seat ring onto the valve body with threads, using the special tools (optional), For the tightening torque, see Table 4-1. (2) Set the plug on the seat ring. (Apply lubricant "Neverseize" to the threaded sections, except those of the oil-inhibited valves.) (3) Put the bonnet on the valve body and check that the bonnet is correctly mated with the indented section of the valve body. Tighten the nuts uniformly, paying attention so that they are not tightened unevenly (tighten alternately the ones located at symmetrical positions). For the tightening torque, see Table 4-3. 4 Insert the gland packing as shown in Fig. 2-1. Note: Whenyarn packing sheets are used, overlap sheets in such manner that their cut ends are positioned alternately. (5). Place the packing follower and packing flange, and tighten the nuts. For the tightening torques, see Table 2-2. © Models HTS, HSC, HPS and HAV (1). Securely fix the seat ring onto the valve body with threads, using the special tools (optional). For the tightening torque, see Table 4-1 or 4-2. (2 @ Set the plug on the seat ring, (Refer to the Disassembly Procedures.) Putasheet of gasket on the valve body side and place the guide ring ina manner of covering the plug. (Apply lubricant "Neverseize" to the gaskets, except those of the oil-inhibited valves.) (4) Put the gasket on the guide ring. (Apply lubricant "Neverseize" to the gaskets, ‘except those of the oil-inhibited valves.) (5) Put the bonnet on the valve body and check that the bonnet is correctly mated with the indented section of the valve body. Tighten the nuts uniformly, paying attention so that they are not tightened unevenly (tighten alternately the ones located at symmetrical positions). For the tightening torque, see Table 4-3. ©) Insert the gland packing as shown in Fig, 2-1. Note: When yarn packing sheets are used, overlap sheets in such manner that, their cut ends are positioned alternately.(7) Place the packing follower and packing flange, and tighten the nuts. For the tightening torques, see Table 2-2. Table 41. HLS, HTS, HLC, HSC, HAV Table 42. HPS Seat Ring Tightening Torques ‘Seat Ring Tightening Torques =n ees Size (in.) | Torque (N-m {kat-cm}) Size (in.) | ANSIClass | Torque (N-m {kgf-om)) als 260 {2,600) 1 200-2,500 250 (2,500) 7 390 {3,900} 1% 900-2,500 310 (3,100) 2% 520 {8,200} 2 900-2,500 570 {5,700} 7 650 {6,500} 3 :200-1,500 4,100 {11,000} 4 800 {8,000} 7 1,200 {12,000} 3 2,500 700 {7,000} 3 1,500 {15,000) 10 (1,800) Table 4-3. Tightening Torque of Bonnet Stud Bolts BOLT Torque (N-m (kgf-em)) Miz 60 (600} M6 100 (1,000), M20 150 {1,500} M22 200 (2,000) | M24 250 (2,500), 27, 350 (3,500) M30 500 (5,000) M33 660(6,600) Table 4-4, Bonnet-Body Bott Size Rating Models | Size (in) ‘ANS|, JPL 150# ‘ANSI, JPI300%, 600% wis 10K wIS 18K, 20K, 30K, 40K HLS wos | mia x4 Mi2x4 1% ote Misx8 2 M16 x 10 2¥ M20 x8 Hitt 3 M22 x10 4 Mze x 12 6 Mao x3 x12 8 M33 x3 x 12 -10-FLANGES Oe Pacinc Ue FLANGE PACKING FOLLOWER stu @ a8 nure2y) A ea STM : L) _-oASKET (2) |_ VALVE STEM 7 VALVE PLUGPACKING FLANGE NUT, Ng PACKING FLANGE PACKING FOLLOWER stu mS cme paceins vex wur(a) TOP GUIDE RING ) an U7 we | _-GASKET(2) ie _UFLAT METAL | SEAT RING For Trim with Cv < 1.0 | For Trim with Cv = 1.0 Fig. 4-3B. Model HPS Control Valves -16-43 Disassembly and Assembly of Actuator Normally the actuator requires no adjustment. However, it should be disassembled and assembled when installing it on a valve body, when modifying its specifications, or when replacing damaged parts. ‘The disassembly and assembly procedure of the actuator for such purposes are covered in Sections 4-4 and 4-5, To disassemble the actuator, refer to Fig. 4-4 to Fig. 4-19. ‘When disassembing or assembling the actuator, keep it in the vertical attitude. For the tightening torques of bolts and nuts, see Tables 4-4, 4-5. For the names of the parts, see Figs. 4-10, 11 and 4-19. 7Notes for Disassembly 1, The nuts for the eyebolts are made of stainless steel, Discriminate these nuts from other nuts when assembling the diaphragm case. 2. Itis recommendable to make locating marks on the top and bottom diaphragm cases before disassembly. This will help you to find easily the air piping connector location. 3. Store the removed parts in a clean place. Caution: Never loosen or remove carelessly the bolts and nuts of the actuator. The actuator employs powerful compressed springs and if you remove the bolts and nuts carelessly, the springs may leap out causing hazards. When removing the bolts and nuts, be sure to observe the instructions given for disassembly and assembly procedures of the actuator and top handwheel.44 Disassembly and Assembly of Model HAI Actuator Disassembly Procedure (a) Direct Action Type (See Fig. 4-5.) (b) (1) Disconnect the air piping and detach the accessories from the actuator. (2) Remove the stem connector. (3) Remove the clamping-bolts (except the pair of eyebolts) of the diaphragm case, (4) Loosen evenly and alternately the pair of eyebolts. (The initial setting of the springs is done by these eyebolts.) (5) Remove the diaphragm case. Pull out upward the actuator rod together with the diaphragm. (6) Take out the springs. Reverse Action Type (See Fig. 4-6.) (1) Disconnect the air piping and detach other external items from the actuator. (2) Remove the stem connector. (3) Remove the clamping-bolts (except the pair of eyebolts) of the diaphragm case. (4) Loosen evenly and alternately the pair of eyebolts. (The initial setting of the springs is done by the eyebolts.) 6 (6) Pull out upward the actuator rod together with the diaphragm. Remove the diaphragm case, Take out the spring.Fig. 4-5. Direct Action Type (HAD) Fig. 4-6. Reverse Action Type (Hat)Assembly Procedure Before assembly, check the parts for scrapes, damage, deformation, peeling off of paint, and other abnormality. To assemble the actuator, proceed as follows: (a) Direct Action Type (@) re GB) 4 6) (6) ”) Fix the bearing (with dust seal) to the yoke. Fix the diaphragm case (bottom) with the four bolts (M10). Fix the spring plate (see Fig. 4-7). Install the springs on the spring plate. Insert the actuator rod (to which the diaphragm is connected) into the bearing, exercising care not to damage the bearing inside surface or dust seal with the threaded section of the rod. (For example, cover the threaded section with adhesive tape to prevent damaging the bearing.) Place the top diaphragm case and fix it with the pair of eyebolts, Notes: @ Set the air piping connection port in the location shown in Fig. 4-7. ¢ Tighten the pair ofeyebolts uniformly by tightening them altenate- ly. The initial setting of the springs is complete by tightening of these eyebolis. Clamp the diaphragm case with other clamping-bolts than the pair of eyebolts. Install the stem connector. (Connect the air pipe to the air piping connection port of the top diaphragm case.) After the assembly is complete as above, check the following. 1. Applying an air pressure of 490 kPa (5 kgf/cm?) via the air piping connection port of the top diaphragm case, check the diaphragm periphery for air leak by using soapsuds. 2. Check that the actuator smoothly operates for its full stroke. Note: Check this operation by operating the actuator as an independent unit. <2t-EYEBOLT LOCATION. AIR PIPING CONNECTION PORT? SPRING PLATE ror) Front Side Fig. 4-7. Direction Action Type (b) Reverse Action Type co) 7) @) ® 6) © 8) @) Fix the bearing (with dust seal and rod packing) and the Oring to the yoke, and fix the bottom deaphragm case with the four bolts (M10). Insert the actuator rod (to which the diaphragm is connected) into the bearing, exercising care not to damage the bearing inside surface or dust seal with the threaded section of the rod. (For example, cover the threaded section with adhesive tape to prevent damaging the bearing.) Fix the spring plate and insall the springs on the spring plate. (See Fig. 48) Place the top diaphragm case and fix it with the pair of eyebolts, Notes: Set the air vent hole in the location shown in Fig. 4-8. Uniformly and alternately tighten the eyebolts, The initial setting of the springs is complete by tightening of these eyebolis. Clamp the diaphragm case with other clampingbolts than the pair of eyebolts. Install the stem connector. Install the rain cap on the air vent port, ‘Connect the air pipe to the air piping connection port of the bottom diaphragm case. After the assembly is compete as above, check the following. 1. Applying an air pressure of 490 kPa{S kgf / cm?} via the air piping connection port of the bottom diaphragm case, check the diaphragm periphery forair leak by using soapsuds. 2. Check that the actuator smoothly operates for its full stroke. Note: Check theis operation by operating the actuator as an independent unit. -22-EYEBOLT LOCATION: AIR PIPING CONNECTION PORT ' SPRING PLATE (BOTTOM) Front Side Fig, 4-8, Reverse Action Type -23-Direct Action Type Reverse Action Type Fig. 48. Bolts and Nuts of Actuator Table 4-4. Tightening Torques of Bolts and Nuts of Actuator No. Material Bolt Size | Tightening Torque (N-m {kgf-cm}) 1 ‘$300 M10 20 to 22 (200 to 220} 2 $30¢ Mio 27 to 33 (270 to 330) 3 s20c Ms 18 to 16 (135 to 165) ‘Suss04 15 10 19 (150 to 195} 4 SUS304 Me 15 to 19 (150 to 195} 5 S206 Me 1410 18 (145 to 180} $US304 16 to 27 {160 to 210) Note 1: Fix the rain cap of the reverse type of actuator as follows: Drive the cap into the diaphragm case until the shoulder (brim) of the cap is brought into contact with the diaphragm case and then drive the cap further into the diaphragm case by half of a turn. = 24-P ©06® © PO O " i o soy 4 8 © = 4 & 8 SO Se SA SS © a) ~~ ; No. Parts Name ‘No. Parts Name |" 1_|_DIAPHRAGM CASE (TOP) 46 [NT 2 EYEBOLT 17 STOPPER COLLAR 3 NUT 18 STOPPER RING 4 DIAPHRAGM CASE (BOTTOM) 19 SPRING 5 BOLT 20 ‘SPRING PLATE. 6 | WASHER 21 BEARING 7 YOKE 22 DUST SEAL 8 ROD 23, POINTER 9 | STEMCONNECTOR Hf | 24 DRIVE SCREW STEM CONNECTOR BOLT 25 ‘TRUSS SCREW 1 ‘CENTER BOLT 26 SCALE PLATE 12. | DIAPHRAGM RETAINER 27 | NAMEPLATE 13 DIAPHRAGM 28 DRIVE. SCREW 14 DIAPHRAGM PLATE 15, BOLT Fig. 4-10. Model HA1 Actuator (Direct Action Type) 28 -@ / id / OS! f / oer) / i Lf —@ 8 (No. Parts Name No. | Parts Name 1_| DIAPHRAGM CASE (TOP) 19 | DIAPHRAGM 2 | EVEBOLT 20_| DIAPHRAGM RETAINER 3 | NUT 21 | O-RING 4 | DIAPHRAGM CASE (BOTTOM), 22_| PACKING FOR ROD Ett 5 | BOLT = 23 | BEARING 6 | SEAL WASHER | 24 | DUSTSEAL 7 | YOKE 2 8 | ROD 26 | DRIVE SCREW 9 | STEM CONNECTOR 27_| TRUSS SCREW ‘STEM CONNECTOR BOLT 28 | SCALE PLATE CENTER BOLT 29 | POINTER ‘STOPPER COLLAR 30_| DRIVE SCREW 7 ‘STOPPER RING 31_| RAIN CAP AND O-RING SPRING. z ‘SPRING PLATE BOLT 7 | NUT DIAPHRAGM PLATE Fig. 4-11. Model HAt Actuator (Reverse Action Typo) = 26-45 Disassembly and Assembly of Model HA2, HA3, or HA4 Actuator Disassembly Procedure (a) Direct Action Type q) @Q) GB 4 ) ) (5) (6) Disconnect the air piping and detach the accessories from the actuator. Remove the stem connector, pointer and lock nut. (See Fig. 4-4.) Remove the clamping-bolts (except the pair of eyebolts) of the diaphragm case. Loosen evenly and alternately the pair of eyebolts. (The initial setting of the springs is done by these eyebolts.) Remove the diaphragm case. Pull out upward the actuator rod together with the diaphragm. Take out the springs. Fig. 4-12, HA2D or HASD Fig. 4-13, HAAD Actuator Actuator 27(b) Reverse Action Type qQ) @ G) (4) 6) 6) Disconnect the air piping and detach other external items from the actuator. Remove the stem connector, pointer and lock nut. (See Fig. 4-4.) Remove the clamping-bolts (except the pair of eyebolts) of the diaphragm case. Loosen evenly and alternately the pair of eyebolts. (The initial setting of the springs is done by these eyebolts.) Remove the diaphragm case. Take out the springs. Pull out upward the actuator rod together with the diaphragm, ee Fig. 4-14, HA2R or HASR Fig. 418. HAAR Actuator ‘Actuator 28Assembly Procedure Before assembly, check the parts for scrapes, damage, deformation, peeling off of paint, and other abnormality. To assemble the actuator, proceed as follows: (a) Direct Action Type (1) Fix the bottom diaphragm case and yoke with the bolts. (For Models HA2D and HA3D, install the diaphragm case and spring plate together.) (2) Install the springs on the spring plate. The quantities of springs are as follows: HA2. 4 springs HA3, HAS. 8 springs Except particular models as follows: HA2, 38 mm stroke, 80 ~ 240 kPa (0.8 — 2.4 kgf/cm?) HA3, 50 mm stroke, 80~240 kPa {0.8 2.4 kgf/cm? HA4, 75 mm stroke, 80 - 240 kPa {0.8 ~ 2.4 kgf/cm? ... Total 8 springs (with double springs) .. Total 16 springs (with double springs) ‘Total 16 springs (with double springs) (3) Insert the actuator rod (to which the diaphragm is connected) into the bushing, exercising care not to damage the bushing inside surface or dust seal with the threaded section of the rod. (For example, cover the threaded section with adhesive tape to prevent damaging the bushing.) Set the stopper in parallel with the yoke. (4) Place the top diaphragm case and fix it with the pair of eyebolts. Notes: @ Set the air piping connection port in the location shown in the illustration. (Fig. 4-16) ‘© Tighten the pair of eyebolts uniformly by tightening them alter- nately. The initial setting of the springs is complete by tightening of these eyebolts, AIR PIPING AIR PIPING ‘CONNECT 10W: CONNECT LON: T PORT FRONT PoRT FRONT SIDE SIDE fa} Crna, 4) Fig. 4-16. Direct Action Type -29-(S) Clamp the diaphragm case with other clamping-bolts than the pair of eyebolts. (©) Install the pointer, secure the lock nut, and install the stem connector. (Connect, the air pipe to the air piping connection port of the top diaphragm case.) 0 After the assembly is complete as above, check the following. 1. Applying an air pressure of 490 kPa (5 kgffem?} via the air piping connection port of the top diaphragm case, check the diaphragm periphery for air leak by using soapsuds. 2. Check that the actuator smoothly operates for its full stroke. Note: Check this operation by operating the actuator as an independent unit. (b) Reverse Action Type (2) Fix the bottom diaphragm case and yoke with the bolts. (2) Insert the actuator rod (to which the diaphragm is connected) into the bushing, exercising care not to damage the bushing inside surface or dust seal with the thread section of the rod. (For example, cover the threaded section with adhesive tape to prevent damaging the bushing.) (3) Make the stopper (in the diaphragm plate) in parallel with the yoke by turning the rod. (4) Install the springs on the spring plate. The quantities of springs are as follows: HA2 HA3, HAG Except particular models as follows: HA2, 38 mm stroke, 80-240 kPa (0.8 - 2.4 kgi/om:)...... Total 8 springs (with double springs) HA3, 50 mm stroke, 80-240 kPa {0.8 - 2.4 kgf/em’}...... Total 16 springs (with double springs) HA4, 75 mm stroke, 80240 kPa (0.8 2.4 kgt/em?)...... Total 16 springs (with double springs) .. 4 springs .. 8 springs 6 Place the top diaphragm case and fix it with the pair of eyebolts. Set the air vent hole in the location shown in the illustration (Fig. 4-17). Uniformly and alternately tighten the eyebolts. The initial setting of the springs is complete by tightening of these eyebolis.© a 8) @) (10) evEBOLT — Cocarton AIR VENT r ale. fn T Port FRONT PoRT FRONT SIDE SIDE [uaz] Cua, 4] Fig. 4-17. Reverse Action Type Clamp the diaphragm case with other clamping-bolts than the pair of eyebolts. Install the pointer, secure the lock nut, and install the stem connector. Install the rain cap on the air vent port. ‘Connect the air pipe to the air piping connection port of the bottom diaphragm case, After the assembly is complete as above, check the following. 1. Applying an air pressure of 490 kPa (5 kgf/cm?) via the air piping connection port of the bottom diaphragm case, check the diaphragm periphery for air leak by using soapsuds. 2. Check that the actuator smoothly operates for its full stroke. Note: Check this operation by operating the actuator as an independent unit. -at-Fig. 4-18. Bolis and Nuts of Actuator Table 4-5. Tightening Torques of Bolts and Nuts of Actuator Unit: (Nem (kgf-omn}) Materiats For HAZ For HAS For HA4 SKS S45C 10 ]57:970)| wate [0s (1.050)! 20 | 310 13,470) s30C Mi2_| 42 (420)| M16 |105 (1,050)] M24 | 360 (3,600) s20c M14 | 69 {690)| Mie |140 (1,450)! M30 | 710 (7,160) szoc Me | 16(160)| Me weii60)| wiz | a2 (420) | ‘SuS304 we [19105 me | terres] wiz | 63 (630) ‘$300 [er 75) 37 (375) 42 {820} M10 Mio iz ‘SUS304 56 (560) 56 (560) 63 (630)Qa BQPRGS ® ® 3 .! g =} |\ 5 u o om o—#4 e— e— a Reverse Action Type (Model HACR) Pans pos] Parts es No. Pans Name No. Part Name se Parts Name 1 [Nur | voKe a fwasien 2_ [OMPHAKGM CASE TOP) 79 [stew CONNECTOR 24 | PAGING 3 [owPHAAGM [pour 25_|ROD 4 [evesout | [15 [owPHmaaM RETANER 26 |LOCKNUT = [wr 16 | stoPPeR 27 _| TRUS SCREW WASHER, NUT) 6 [sou 7_[DMPHRAGM PLATE 28_|SOALE PLATE 7_ [DIAPHRAGM CASE @OTTOW || 18 [CoN SPRANG | |screw 8 | BUSHING 19 (BOLT 30 | NAMEPLATE 9 | BEARING 20 |NuT 31 | CAP 10 [DUST SEAL 21 [Senna PLATE w oANG 11 [PORTER @ [sor ao | WASHER ce i 34 | TAPPING SCREW PEE Fig. 4-19. Cut View of Actuator4.6 Disassembly and Assembly of Model PSA6 Actuator 4.6.1. General ‘Structure This actuator consists of cylinder, spring unit, lift stopper, spring retainer, hexagon stay, yoke, manual handwheel and single action positioner. For external appearance of the actuator, refer to Fig. 4-20, External Appearance of PSAGR. (1) Without manual handwheel (2) With manual handwheel Fig. 4-20 Exterior of PSA6R. Assembly on valve body. Assembling nuts integral to the valve body assembles yoke and valve body. Stem connector connects actuator’s rod and valve stem. p oe ‘The tubing is connected to single action positioner when used as control valve, Refer to the follow- ing instruction manuals for details of single action positioner. Pneumatic positioner (Model HTP) No. OM2-8310-0200 Electro-pneumatic positioner (Model HEP) _ No. OM2-8310-0100 Electro-pneumatic positioner (Model AVP300/301) ‘No, CM2-AVP300-2001 -34-Calibration ‘This actuator does not need calibration, ‘When connecting valve stem of the valve body with actuator’s rod with stem connector, due adjust- ment should be made to seat the valve plug on the seat ring. Then screws on actuator’s scale plate are loosened, stroke and index matched to properly position the scale plate. + When automatically operating an actuator with manual handwheel, verify that the AUTO/MANUAL switchover pin is inserted into pin holder, chain is engaged on the handwheel and the indicator is in AUTO position] before start of operation. + When disassembling and assembling, always hold the actuator in upright position (spring unit on top and yoke on bottom) + While eyebolts are used to suspend actuator, assembled valve should not ‘be suspended by eyebolts only =25-4.6.2 AUTO/MANUAL switchover of manual handwheel Refer to Fig. 4-21 for details of AUTO/MANUAL switchover of handwheel. With an actuator with AUTO/MANUAL switchover functions, switchover between automatic opera- tion and manual operation by handwheel are available. AUTO/MANUAL switchover can be made at any optional moment during operation, Im MANUAL position Fig. 4-21 AUTO/MANUAL switchover scheme Fig. 4-22 Operator's instruction label = 36+Match the round holes of sli Procedure Pull out AUTO/MANUAL switchover pin out of holder and disengage chain, which binds handwheel from the wheel. ‘Verify operating label on handwheel and turn the handle to thedirec tion of SHUT and lower slide screw. screw and actuator’s rod, and insert pin. Push it all the way in and fix it there. Verify OPEN, SHUT arrows on label, and turn the handwheel to cither direction to open or close the valve. The turning torque should be under 127N (13kgf) ‘When the handwheel does not turn any further, check valve opening and end operation. A Caution Do not apply undue force on valve when it | teaches mechanical stop. Otherwise valve [ stem may be damaged. Refer to 10, Trouble shooting for remedial action. To resume automatic operation, remove the switchover pin, turn handwheel until ‘The slide screw stop reaches AUTO position (refer to Fig, 4-23 below), Run the chain on the pin through in order to restrict handwheel movernent and fix the pin on holder. Resume automatic operation after verifying this condition, Fe) 37-4.6.3 Disassembly and assembly of actuator Disassembly and assembly procedures are described herein. Refer to it whenever necessary for peri~ odic maintenance or malfunction which may call for disassembly or assembly of the actuator. Refer to pages 18, * “Note for Disassembly.” ‘Separating valve body from actuator Refer to pages 8, 4- 1 DetachingActuator from Valve Body. Disassembly of actuator Disassembly procedure of actuator is described herein, Refer to pages and ® Marki Figures 4-24 and 25 for information. yz and protection ESEERERSERERSSODZ -Butananasmns onsen a navannanantnaatanaatanaas Match mark on spring retainer on the top of actuator, lift stopper, | oylinder and cylinder assembling yoke boss. Wrap PVC tape on rod bushing to protect sealing parts, guide bushing. SES du Ses ISESESESEESICN 7.0% BODESESIEEOEEES Loosen hexagon head bolt No.49 and hex nuts No.51 which fasten slide screw detent No.49 [Remove slide screw detent No.49 @_ Removing spring retainer Procedure Loosen hexagon nuts No.2 and eye nut No.1 on the top of actuator and remove. Lift spring retainer No.17 straight up and remove. ~38-@ Removing lift stopper and spring unit Step. T ‘No.9 (four) which fasten lift stopper ‘No.20 and cylinder No.21 and remove E Raise lift stopper No.20 straight up and remove. Install eyebolts on threaded holes on the spring retainer which is located on the top of spring unit (M12 x 2) and lift spring unit (approximately 120 kg) up with a crane. While suspended by crane, remove piston’s No.57 sealing parts (tape li O-ring 8) ® Removing slide screw and cylinder = EEE @©_ Removing worm unit H =H Procedure Tum slide screw No.34 by hand and extract from the bottom Loosen hexagon head bolts No.12 (four) which fasten cylinder | and manual handwheel and remove. ifi cylinder up straight and remove. PEE Step Procedure 1 Remove in the sequential order of bearing holder No.27, single column angular bearing, (upper) No.32, worm wheel No.33, and single column angular bearing (lower) No.32. Loosen hexagon head bolts No.12 (four), which fasten gear, case ‘No.30 and yoke and remove.Fig. 4.24Fig. 425 Spring Unit Table41, Parts reference List Parts nomenclature No. | Parts nomenclature Eye nut 33_| Worm wheel | Hexagon nut 34. | Slide screw ‘Spring washer = 35 | Locking pin Hexagon stay (long) 36 | Handwheel Oring 37_ | Operating instruction label Piston unit 38_| Spring washer Tape liner 39. | Locknut ‘Oring 40_|Single column bearing Hexagon stay (short) 41_|[ Worm shaft HEE Seal washer 42 [Key Spring washer 43. | Gearcase cap 12 | Hexagon head bolt 44 | Dust seal Ee 13 [Round bushing 4 _| Hexagon head bolt 14 [Dust scal 46_ | Spring washer iz [15 | Wearing 47. | Truss screw, small 16 [Nameplate 48 _| Indicator 17. {Spring retainer 49. | Slide serew lock 18 [Rain shield cap 50 | Hexagon head bolt (19 |Oring ee ~_|[51_|Hexagon nut 20. |Lift stopper 52. | Hexagon nut 21 [Cylinder 53. | Stopper retainer [22 [Rod packing 54 | Spring (large) 23 | Guide bushing 55_| Spring (small) 24 [Dust seal 36_| Spring stopper 25 |Scale plate 57. | Piston 26 | Truss screw, small 58 | Rod 27 [Index 59 _| Spring receptacle 28 [Stem connector 60 Stopper [29__|Yoke 61_| Detent nut 30 |Gearcase ‘Spring washer [31 _|Bearing holder Orns a 32. | Single column angular bearing a Disassembly procedure of spring unit is described herein. Refer to Figure 4-25 for disassembling information. Disassembling is not required if only piston’s scaling parts (tape liner, O ring) are replaced. @ __ Removing spring unit Step Procedure 1 _ | Loosen hexagon nuts No.52 (four on top) and remove 2 Remove stopper retainer No.53 3 | Evenly loosen hexagon nuts 52 (four on bottom) until tension of springs 54 and 55 becomes zero. Follow disassembly procedure of spring unit when removing bolts and nuts. Otherwise, flying out of spring may cause 4 | Remove spring retainer 59 5 2 | Loosen detent nut No.61 and remove. ___| Take advantage of double width of rod No. 3 | Remove spring washer No.62, O-ring No.61. Exercise care so as not to damage O ring with rod’s screw. 4 | Separate rod 58 from piston No.57.Assembling actuator + Refer to the chapter of inspection items during disassembly and check, and ensure that no abnormality is found on parts. If found, replace or repair as required. + O-ting of sliding parts should always be replaced at the time of periodic disassembly. Whenever ‘O-ring on the fixed part is deformed or damaged, or scarred during disassembly, replace it. * Clean O ring, oil seal, wearing, tape line O-ring recess and apply plenty of lubricant. + Ensure that no dust or dirt from maintenance work prior to disassembly remains on sliding part of cylinder and guide bushing, Assembly of actuator with manual handwheel Refer to Figure 4-24 for assembly information. ® Assembly procedure, manual handwheel and cylinder assembly Step 1 2 Procedure While yoke is in upright position, place gear No.30 and temporarily fasten with hexagon head bolts No.12 (four) ‘Apply lubricant on single column angular bearing (top and bottom) and assemble in the sequential order of bearing (lower) No.32, worm wheel No.33, bearing (upper) 3No.2 and bearing holder 31. Refer to the Figure 4-26 below for details. ig. 4-26 Insert and screw in from the bottom slide screw No.34 with tape Jiner No.13 assembled on. Apply lubricant on threaded parts of slide serew No.34, Assemble slide screw No.34 with slide screw detent No.49, hexagon. head bolt No.50 and nut No.51. ‘Apply lubricant on rod packing No.2 and dust seal No.24 and assemble on cylinder No.21. 4a.Step | Procedure “6 [Place cylinder No.21 on gear case No.30 and temporarily fasten by hexagon | head bots No.12 (four) 7 | Use rod No.58 to set the position of cylinder by ensuring that the rod | moves smoothly and tighten by the torque as shown in page 5-12, table 5-2. If the rod does not move smoothly, tap cylinder or gear case with plastic hammer and set the position. @ Assembling piston unit, lift stopper and spring retainer Procedure | Install eyebolts on threaded hole (M12 x2) on the top of spring retainer No.59 on the piston unit, suspend by crane and lift upright. While suspended upright, assemble lubricated O ring No.8 and tape | liner No.7 on piston No.57. ‘Assemble piston unit in cylinder No.21 from the top. See to it that the round hole of rod No.58 appears front ‘Assembie lift stopper O-ring No.5 in the slot on the top of eylinder Nol. _ Insert lift stopper No.20 from the top and fix by hexagon stay No, No.9 (four). Screw on the ones of same length diagonally “Assemble so that the hexagon stays No.4, No. arc fit into holt holes ___| of spring retainer Ni Fix spring retainer with hexagon head nuts (four) Install eye nuts No.1 (two) on hexagon stay No.4 oe eee When assembling actuator without manual handwheel, follow the procedure in “4-3 Assembly of actuator with nut manual handwheel” except the applicable parts to actuator.4.6.4 Major replacement parts ‘Actuator’s parts have been designed to withstand prolong usage. However, itis recommended that the following parts be replaced in the interval as shown below: ‘Tape liner —- Busing ‘Seal washer : Dust seal =” Rod seal —- . Oring- very five years (to be replaced when disassembled) ¢ ¢ Tightening torque of actuator assembly Table below shows tightening torque of actuator assembling. Refer to Fig. . ) ef ) 4-27. tightening torque of actuator’s threaded parts. Key No. | Size Tightening torque [N-m] ® Mi4 800-1200 @ M20 2700 - 3650 - ® M24 3050-4150 ® Mit 800 1200 ® MI2 500 - 600 Table. 4-2 Fig. 4-27 Tightening torque of actuator threads5, ADJUSTMENT As a general rule the diaphragm type control valves require no adjustment. However, when coupling an actuator to a valve body after removing the actuator for overhaul or other purposes, adjustment of travel (stroke) is necessary. For this adjustment, refer to Fig. 4-4, Fig. 5-1 and proceed as follows: (1) Fixthe actuator to the valve body by securely tightening the yoke clamping-nut (use a chisel and a hammer), (2) Connect an adjustable air pressure (with a pressure regulator) to the actuator — to the top diaphragm case for the direct action type or to the bottom diaphragm case for the reverse action type. (3) Lower the valve seat and check that it is contacted with the valve seat. For the Direct Action Type (4) Apply to the actuator the maximum air pressure corresponding to the spring range indicated on the nameplate. (5) Increase the air pressure to the supply pressure and check that the actuator stem moves by 1-2mminresponse. (This movement represents the allowance of stroke.) (6) Decrease the air pressure once, Then increase it again to the maximum value corresponding to the spring range, in the increasing direction. (7) Inthe above state, align the actuator stem and valve stem on a straight line, adjust so that the thread of the stem connector mates with those of actuator stem and valve stem, and securely tighten the clamping-bolts of the stem connector. (See Fig. 5-1.) For the Reverse Action Type (4) Apply to the actuator the minimum air pressure corresponding to the spring range indicated on the nameplate, and check that the actuator stem moves by 1-2 mm in response, (5) Increase the air pressure once. Then decrease it again to the minimum value corresponding to the spring range, in the decreasing direction. (© Performa procedure identical with that of Item (7) of "For the Direct Action Type." (See Fig. 5-1.) = 46ACTUATOR STEM Set at maximum or miniaum value of spring range (For direct or reverse action) by jnoving actuator stem in this direction. -47-6. DIRECT / REVERSE ACTUIB TYPE CONVERSION AND SPRING RANGE CHANGE OF ACTUATOR 6.1 Direct / Reverse Action Change ‘As a general rule it is most recommendable to prepare separately the direct type and reverse type of actuators and not to convert actuators into different types. However, when it has become unavoidable to convert actuators into other types, conversions may be done by using the parts mentioned below (Table 6-1 and Table 6-2). The parts marked "+" are the ones which are newly needed and those marked *=" are ones which are not used. Table 6-1. To Convert the Direct Action Thpe into the Reverse Action Type HAID > HAIR Parisname | Qty ‘Seal washer +4 | _80352967-006 Rod packing 82521067- Rain cap, 82553334-101 '82592130-401 '82502225-396 HA2D > HA2R- Partname | Qiy | For stroke 14.3mm, 25mm | For stroke 38mm. Seal washers | +4 | 62521069-101 €2521069-101 Rod packing | +1 | _€2521067-101 €2521067-101 Rod unit +4 | 82521431-101(4. 3mm) 82521431-103, ae |_82521431-102 (25mm) cee Rain cap '82553334-101 82553334-104 Rod '82521427-101 (14.amm) 82521427-103 82521427-102 (25mm) HASD — HASR Partname | Qty | For stroke 14.3mm | For stroke 25mm, 36mm | For stroke 38mm Seal washers | +2 8252169-102 '82521068-102 '82521069-102 Rod packing | +1 | 82521067-102_ | 62521067-102 '82521067-102 Rod unit +1 | €2521431-201 | 62521063-103 25mm) €2521431-204 82521063-104 (38mm) Rain cap +1 | 2653934-101 | 62553334-101 82553334-101 Rod 1) | €2521428-101_ | 62521428-102 @5mm) 82521428-104 82521428-103 (8mm) HAD — HAI Partname [Qty For stroke 25mm. For siroke 38mm, 50mm, 75mm Seal washers | +2 82521069-103 82521069-103 Rod packing +1 82521067-103 '82521067-103 Rod unit +4 82521431-302 '82521431-303 Rain unit ao} 82521429-102 82521429-103 (Emm) 82521429-104 (50mm) 82521429-105 (75mm) | Rain cap +1 82553334-101 '82553334-101 Flat washers | 2) 82592131-201 '82592131-201 -48--Table 6-2. To Convert the Reverse Action Type into the Direct Action Type HAIR HAID Partsname | Qty ‘Seal washer =4 '80352967-006 Rod packing 4 '62521067-104 Rain cap 4 82553334-101 ‘Washer +4 '82592130-401 “O* ring 4 '82592225-396 HAR — HA2D. Partname | Qty For stroke 14.3mm, 25mm For siroxe 38mm. ‘Seal washers | (2) 82521069-101 '82521068-101 Rod packing (1) '82521067-101 '82521067-101 Rod unit +4 82521427-101 (143mm) 82521427-103 82521427-102 (25mm) Rain unit CD 82521431-101 (14.3mm) ‘B2521431-103 82521431-102 (25mm) Rain cap CD. 82553334-101 7 §2553334-101 HASR > HASD Partname | Qty _| Forstroke 44.3mm | Forstroke 2mm, 38mm | For stroke 50mm. Sealwashers | (2) | 82521069-102 '82521069-102 82521069-102 Rod packing | 1) | 82521067-102 '82521067-102 82521067-102 Rod unit +4_[ 62521428-101 82521428-102 (25mm) 82521428-104 82521428-103 (38mm) Rain unit A) 82821431-207 82521431-202 (25mm) B2521431-204 ie 82521431-203 (38mm) Rain cap €4)_|- 82555834101 82553334-101 82553334-101 HAAR —> HA4D. Part name ay For stroke 25mm, For stroke 38mm, 50mm, 75mm Seal washers_| 2) 82521069-103 '82521069-103 Flat washers +2 82592131-201 82592131-201 Rod packing ©) 82521067-103 '82521067-103 Rod unit a) 82521431-302 '82521431-303 Rain unit +4 82521429-102 82521429-103 (38mm) 82521429-104 (50mm) 82521429-105 (75mm) Rain cap cD 82553334-101 82553334-101 For the conersion procedure, refer to Section 4 "DISASSEMBLY AND ASSEMBLY."6.2 Stroke And Range Spring Change Asa general rule it is most recommendable to prepare separate actuators for diffent strokes and spring ranges to avoid modifications. However, modifications can be done by using the parts mentioned below. Of Models HA2 and HA3, there are two different deameters of bonnet connectiong sections. For these models, note the following: Of Model HA, modification for change between raed stroke of 14.3 or 25mm and that of 38mm cannot be done. Of Model HA3, modefication for change between rated stroke of 25or 38mm and that of 50mm cannot be done. ‘Table 6-3, Parts Required for Respective Stroke Ranges Note: Spring force is equivalent to ar pressure (KPagegtem') ‘Aatuator HAID > HAIR Part name Gly [Stroke 25 5 4.3mm Stroke 14.3 > 26mm Scale plate i 82521348101 82521343-101 Spring | 7os8;207) [4 82521340-101 82521340-104 0200824 | 4 82521340-102 82521341-103 Center bot 1 82521360-327 82521350-127 ‘Stopper color 1 82521338-103 82521338-101 | Rod unit i 82521342-103 82521342-101, ‘Actuator HA2D > HAIR Partname Giy [Stroke 25 14.3mm Stroke 14.3 > 25mm ‘Scale plate 1 '80225032-164 80225037-164 Spring | 20887020) 4 '82521205-101 82521205-103 e020 b24 [a '82521205-102 82521208-101 Rod unit | ® feversesctony_| 4 182521431-101 82821431-102 D (rect aciony | t '82621427-101, 82521427-102 {| Actuator = HA3D — HA3R Part name Qty [Stroke 38 + 25mm ‘Stroke 25 — 38mm Scale plate i '80225037-164 '80225030-164 Spring | 20880207) 8 '82521206-101 '82521206-103 2020 (0624 | 8 '82521206-102, '82521209-101 | Rod unit [R Reverse actor) [7 82521431-202, 82521431-203, Breet aston) [4 82521428-102, 82521428-103,Actuator HAAD —> HAAR Part name Qiy | Stroke 25mm | Stroke 38mm _| Stroke 50mm_| Stroke 75mm. ‘Scake plate {| 80225037-164 | 80225038-164 | 80225041-164 | _80224425.164 Spring | O5 @ | e2szized-104 | “ezerI207-101 | _82521207-102 | 82521210-103 80-240 @ | szenizaa-10e | azsria10-101 | S2521210-102 | e2sz1210-106° 4082.4) 82521210-105" ROG UTE YR eum |__| SZABO TOR | BRERTADI-TOS | exsDTaDe-AOe | 82521420-105 o 7 | smeaiasi-a02 | e2srt4at-303 | e2s21431-303 | 82521497303 (Direct action) *: The quantity of springs is 8 set, with 2 springs for each set, or total 16 springs. Color Codes and Dimensions of the Springs of Model HA Actuators ‘The color codes and dimensions of the springs of Model HA Actuators are as shown in the following table. The color codes may help you confirm springs when disassenmbing and assenmbling actuators for modefication or other purpose. Table 6-4, Color Codes and Dimensions of Springs (mm) Model Rates HAt HAZ HA3 HAS stroke Range 43 20-08 Red Red | Yellow and Green (02-40 64.6 86 99.2 80-240 Blue Blue Red and Green {0.8-2.4) 69.8 90 103.6 2 20-98 Green| ~ Yeliow Red Yellow and Green 40.2-1.0) 68.7 O14 3 148.1 80-240 Purple | Brown Blue Red and Green 40.8-2.4) 788 99 107 155.3 38 20-98 Green Yellow Red 10.2-1.0) 95 102.9 152.8 80-240 ~| Purple Brown Blue 40.8-2.4) 107 114.9 163.7 50 20-98 Green Yellow {0.2-1.0) 106.5 156.3 80-240 Purple Brown 40.8-2.4) 122.2 1708 7 20-98 Green 40.2-1.0) __ 163.4 80-240 Purple NOTE 1 {0.8-2.4) 182, 186.7* Note: 1. Each set is comprised of two springs. 2. *0.2-1.0" and *0.8-2.4" are spring forces corresponding to air pressures in the unit of kPatkafiom?}. 3. The dimensions indicated in the Table 9 are ree lengths of springs. -5t-7. INSTRUCTIONS FOR TOP HANDWHEEL OF ACTUATOR 7.1 Model HAI Actuator 7.4.1 Operating Instructions To manually operate the actuator, refer to Fig. 7-1 and Fig, 7-2 and proceed as follows: (1) Loosen the lock nut of the handwheel and turn the handwheel in the direction Q indicated by the corresponding arrowhead mark. Asyou turn the handwheel clockwise, the actuator stem moves downward regardless of whether the actuator is of the direct action type or reverse action type. The handwheel bears the "SHUT" mark to indicate that the valve is closed as the handwheel is turned clockwise and the "OPEN" mark to indicate that the valve is made open as the handwheel is turned counterclockwise. For automatic operation of the actuator, fully raise the handwheel if the actuator is of the direct action type or fully lower the handwheel if the actuator is of reverse action type, and then tighten the lock nut to secure the handwheel in such position. Precautions: If you forcefully turn the handwheel after it has reached the mechanical stop position, the valve stem may be damaged. Do not turn the handwheel with forces larger than 16 kgf at the outermost periphery of the handwheel. - 82Nas Pars Name Tet are Name [1 FaNOWrEEL 25” | cENTeRBOLT 2 10iewt 25 | _ DIAPHRAGM RETANER, 3_[ HOUSING 27_|__ DAPHRAGM | ORNG 25 | DAPHRNGM PLATE 5 | WASHER 29_|_Bour —8 | ona 90 [eer 7 ‘SEAL WASHER [st ‘STOPPER COLOR. EE 3 | sar z 32_|_STOPPERRING ~9__[_ DAPHRAGM CASE (TOF) 33_|__sPAING wo | ever 34 [SPRING PLATE | Nur i 35__| BEARING 12_| DIAPHRAGM GAE (GOTTOW 36] DUST SEAL 13_| BOLT a7_| POINTER 1a [Wastin 38 | DAVE SCREW 35 [YOKE 39 | TRUSS SOREW 16 | ROO reer ere eere 40 | SCALE PLATE wv STEM CONNECTOR. wn NAMEPLATE Pee Poet 16 | STEM CONNECTOR BOLT “42 | DAWE SCREW 19 |_Nor Perera 20__ | SPRING WASHER 21 | WASHER 22 | SCREW SHAFT 23 [SPRING PIN 24_| BEARING Fig. 7-1. Model HAt Actuator with Top Handwheel (Direct Action Type)Ret Pare Name Nea Pars Name 1 | _HANDWHEEL 2a | BEARING 2 | LOcKNUT 25 _|_ CENTER BOLT f 3_{_HOUsNG 25 | _ OINPHRAGM RETAINER 4_|_WASHER 2r_| SCREW 5 _|_ SPRING PIN 28__|_ SPRING 6 |_Nur ete 29__ | SPRING PLATE 7 | 80uF 30__| BOUT & | CAPANDORNG a1 | NT ‘9 | DIAPHRAGM CASE (TOP) '32_| DIAPHRAGM PLATE: 10_|_EvESOLT 33__| DIAPHRAGM 11__| BEARING CASE in ‘34 | DIAPHRAGM RETAINER 2 [NUT 35) O-ANG [1a_| “DIAPHRAGM CASE (BOTTOM) '36__|_ROD PACKING | sour 37) BEARNG. ee 35 _|_ SEAL WASHER '38__| OUST SEAL 16 | YOKE a ‘30 | NAMEPLATE 17 | ROD. 40 | _ onve SCREW = “18 |” STEM CONNECTOR 41_| TRUSS SCREW. 49_| STEMCONNECTORBOLT__ 42 | SCALE PLATE 20 [nur 43__| POINTER 2t__|_ SPRING WASHER = 44 [DANE SCREW 22 WASHER "23 | SCREW SHAFT Fig. 7-2. Model HA1 Actuator with Top Handwheel (Reverse Action Type) <47.12. Disassembly and Assembly of Top Handwheel To disassemble or assemble the top handwheel, refer to Fig. 7-1 through 7-4 and proceed as described in this section. For disassembly work, keep the actuator in the vertical attitude. @ (b) Direct Action Type (1) Disconnect the air piping. (2) Set the handwheel shaft in the automatic operation position (fully raise the handwheel shaft). (3) Remove the top diaphragm case. When doing this, loosen the pair of eyebolts uniformly and alternately, after removing all other clamping-bolts of the diaphragm case. 4 Sufficiently insert the handwheel shaft by turning it and then remove the handwheel and the lock nut. Insert the shaft further and then remove the screw shaft from the housing. (5) Remove the O-ring. To assemble the top handwheel, follow the disassembly procedure in the reverse order, Reverse Action Type (1) Disconnect the air piping, (2) Set the handwheel shaft in the automatic operation position (fully lower the handwheel shaft). Remove the handwheel and the lock nut, Insert the shaft into the housing by means of the threading until the threaded sections are disengaged. 3 (4) Remove the top diaphragm case. When doing this, loosen the pair of eyebolts uniformly and alternately, after removing all other clamping-bolts of the diaphragm case. (5) Remove the housing by loosening its clamping-screw. (6) Remove the setscrew and then remove the bearing case. (7) Remove the spring pin and then remove the castle nut. @) To assemble the top handwheel, follow the disassembly procedure in the reverse order. Remove the bearing retainer and then remove the bearing.(© Inspection After Assembly (1) Check that the handwheel turns smoothly for the full stroke. (2) For the direct action type of actuator, check by means of soapsuds that there is no air leak from the connecting section of the top diaphragm case. Fig. 7-3. Modet HAt Direct Fig. 7-4, Model HAt Reverse Action Type Action Type = 56-7.2 Model HA2, HA3, or HA4 Actuator 7.24 Operating Instructions To manually operate the actuator, refer to Fig. 7-5 through Fig. 7-8 and proceed as follows: (2) First, loosen the lock nut (which has a bar-shape handle and which locks the handwheel) and turn the handwheel in the direction indicated by the corresponding arrowhead mark. Asyou turn the handwheel clockwise, the actuator stem moves downward regardless of whether the actuator is of the direct action type or reverse action type. The handwheel bears the "SHUT" mark to indicate that the valve is closed as the handwheel is turned clockwise and the "OPEN" mark to indicate that the valve is made open as the handwheel is turned counterclockwise. (2) For automatic operation of the actuator, fully raise the handwheel if the actuator is of the direct action type or fully lower the handwheel if the actuator is of the reverse action type, and then tighten the lock nut to secure the handwheel in such position. Precautions: _ Ifyou forcefully turn the handwheel after it has reached the mechanical stop position, the valve stem may be damaged. Do not turn the hand- wheel with forces larger than the below-mentioned limits. Model HA2: 190N (19 kgf} Model HA3: 260 N (26 kgf} Model HA4: 410N (41 kgf} (at the outermost periphery of the handwheel) -87-Pars Name } NUT WASHER, “HANDWHEEL ‘SCREW SHAFT LOCK NUT, ORNG. COTTER Nor DIAPHRAGM CASE (TOP) EYEBOLT | NUT i ‘THROUGH BOLT DIAPHRAGM DIAPHRAGM CASE (BOTTOM) BUSHING BEARING. DUST POINTER, YOKE ‘STEM CONNECTOR ‘STEM CONNECTOR BOLT HOUSING. BEARING ‘SPRING RETAINER RING ‘SEAL WASHER. ‘BOLT | —— | ‘DIAPHRAGM RETAINER i ‘STOPPER i DIAPHRAGM PLATE. ‘BOLT ‘NUT ‘COMPRESSED COL SPRING ‘SPRING PLATE ‘BOLT ‘SPRING WASHER ROO LOCK NUT, ‘TRUSS SCREW, SPRING WASHER NUT, OR SPEED NUT SCALE NAMEPLATE DAVE SCREW WASHER, "TAPPING SCREW Fig. 7-5. Model HA2/3 Actuator with Top Handwheel (Direct Action Type)Parts Name aa wae or Toa Sone gtaeT | BEARING CASE, or CoG RE TOM sever @ a m i RoE @ 2 GE meee —— ‘3 | CoRNECTOR 20) 14_| DIAPHRAGM CASE (BOTTOM) |» [col | =| 5 @ | is | Cstopen ' 5 ‘6 | OMPHRNGH RETAINER 7 | BEANS ie | eusHNG sy) 19 YOKE &) 20 | "LOOK RT ar | —rowren << 22 STEM CONNECTOR 83 23_| _ STEM CONNECTOR BOLT a 4 24 HOUSING 9 25 | BEARING WASHER —~ ae | Bem o 27 | comeR EW | & “26 | castu Nur @ 4) G8) 29 SEAL WASHER (5 5 a 9 30 | “sou | so © at | COMPRESSED OOH PANE 9 o 22| —seTScREW 2 BRO | serecrew | ( a4 | 800 G | 3 LO 35_| Nut 2 [26 | “paPana TE | é a7 | “sPAna pate @) 38 BOLT @ © 30_| SEN. WASHER ae o 40 | Pacing FOR AOD a1 | bust SEAL fa | TRUSS SCREW, SPRING WASHER NUT.ORSPEEDNUT w_[ sole a ‘ROD et 4s NAMEPLATE. = 46" orve Screw 7 [sre WASHER ie [Donna Fig. 7-6. Mode! HA2/3 Actuator with Top Handwheel (Reverse Action Type) -59-z G ‘SCREW SHAFT LOCK NUT ‘BEARING ‘BEARING CASE “COTTER, 10 |0|~1|o»en} » | co) m0] F ‘CONNECTOR 30_|EYEBOLT 11 | _NUT ‘2_| THROUGH BOLT 13__|_ DIAPHRAGM CASE (BOTTOM) 14 | COW SPRING 15_| BEARING 18 | BUSHING 7 [ROO POINTER. 8 19 | LOCK NUT 20 | YOKE _21_| _ STEMGONNECTOR ‘STEM CONNECTOR BOLT. ‘HOUSING PISTON PLATE, ‘O-RING ‘BOLT | BEARING RETAINER ‘SEAL WASHER [pour es fo ms Js foe 22/28 |“ oprnacu Case Toy] [Tat pneerat DIAPHRAGM PLATE BOLT NUT ‘STOPPER BOLT ‘SPRING PLATE WASHER, ‘OUST SEAL. loll le ‘SCALE ‘TRUSS SCREW, SPEED NUT_ NAMEPLATE DRIVE SCREW. O-FING ‘SEAL WASHER KEYBOLT SETSOREW. SETSCREW. SPRING WASHER igislalsiejalelals DIAPHRAGM RETAINER Fig. 7-7. Model HA@ Actuator with Top Handwheel (Direct Action Type)5 Parts Name NUT ‘WASHER, HANOWHEEL LOCK NUT ‘SCREW SHAFT ‘BEARING CASE CAP. DIAPHRAGM CASE (TOP) EYESOLT NUT, THROUGH BOLT DIAPHRAGM DIAPHRAGM CASE (BOTTOM) ‘STOPPER. (CONNECTOR. DIAPHRAGM RETANER, ‘BEARING. BUSHING YOKE. ROD POINTER, ‘STEM CONNECTOR ‘STEM CONNECTOR BOLT HOUSING. ‘WASHER, ‘BEARING COTTER PIN (CASTLE NUT ‘SEAL WASHER, BOLT ‘COIL SPRING. SETSCREW BOLT NUT __SETSCREW DIAPHRAGM PLATE ‘SPRING PLATE BOLT ‘SEAL WASHER. PACKING DUST SEAL ‘TRUSS SCREW, SPEED NUT SCALE LOCK NUT NAMEPLATE DRIVE SCREW KEY BOLT, SPRING WASHER O-RING. || |e i]s ex oe ies fs es [ss foe | as | SSS |S a SSS Fig. 7-8. Model HA4 Actuator with Top Handwhee! (Reverse Action Type) <6t-7.2.2 Disassembly and Assembly of Top Handwheel To disassemble or assemble the top handwheel, refer to Fig. 7-5 through 7-10 and proceed as described in this section. For disassembly and assembly work, keep the actuator in the vertical attitude, (a) Direct Action Type ©) (G (1) Disconnect the air piping. (2) Set the handwheel shaft in the automatic operation position (fully raise the handwheel shaft), (3) Remove the top diaphragm case, When doing this, loosen the pair of eyebolts uniformly and alternately, after removing all other clamping-bolts of the diaphragm case. (4) Sufficiently insert the handle shaftby turning it and then remove the handwheel and the lock nut, Insert the shaft further and then remove the screw shaft from the housing, (5) Remove the O-ring. To assemble the top handwheel, follow the disassembly procedure in the reverse order. Reverse Action Type (1) Disconnect the air piping. @ Set the handwheel shaft in the automatic operation position (fully lower the handwheel shaft). (3) Remove the handwheel and the lock nut, Insert the shaft into the housing by means of the threading until the threading sections are disengaged. (4) Remove the top diaphragm case. When doing this, loosen the pair of eycbolts uniformly and alternately, after removing all other clamping-bolts of the diaphragm case. (5) Remove the housing by loosening its clamping-screws. (6) Remove the setscrew and then remove the bearing case. (7) Remove the pin and then remove the castle mut. (8) Remove the bearing retainer and then remove the bearing. To assemble the top handwheel, follow the disassembly procedure in the reverse order. Inspection After Assembly (1) Check that the handwheel turns smoothly for the full stroke. (2) For the direct action type of actuator, check by means of soapsuds that there is no air leak from the connecting sections of the housing and top diaphragm case. 62+8. INSTRUCTIONS FOR SIDE HANDWHEEL OF ACTUATOR As you turn the handwheel clockwise, the actuator stem moves downward regardless of, whether the actuator is of the direct action type or reverse action type. The handwheel bears the "SHUT" mark to indicate that the valve is closed as the handwheel is tuned clockwise and the "OPEN" mark to indicate that the valve is made open as the handwhee! is turned counterclockwise. 8.1 Installation Procedure To install the side handwheel, refer to Fig. 81 and proceed as follows: (1) Prepare amanual operation kit (aside handwheel set and its mounting accessories). To install the handwheel, no machining or other physical processing on the actuator is necessary. (2) Byturning the handwheel, set the pointer of the operation nutat the AUTO position. (3) Loosen the bolt (item number @ as shown in Fig. 8-1) and widen the distance between levers. (4) Install the handwheel on the mounting pad at the back of the actuator, with the mounting-bolts, (5) Engage the holes at the end of two levers to the pointer boss and engage those of the other ends to the boss of the operation nut, and then tighten the bolt. (6) When the control valve is in the automatic mode of operation, set the pointer of the operation nut at the AUTO position and keep the handwheel locked. 8.2 Operating Instructions (2) To manually operate the actuator, remove the handwheel lock (the fork-shaped component) which locks the handwheel and turn the handwheel in the direction indicated by the corresponding arrowhead mark. (2) To return to the automatic operation, turn the handwheel so that the pointer of the operation nut is set at the AUTO position and then apply the handwheel lock. Precautions: Ifyou forcefully turn the handwheel after it has reached the mechanical stop position, the valve stem may be damaged, Do not turn the hand- wheel with forces larger than the below-mentioned limits. Model HA2: 190N {19 kgf} Model HA3: 290 N {29 kgf} Model HA4: 460 N (46 kgf} {at the outermost periphery of the handwheel) 83 Disassembly and Assembly of Side Handwheel (Refer to Fig. 8-1) Before starting disassembly, check that the pointer is set at the AUTO position. (1) Loosen the bolt © which connects the levers @) and then disengage the levers from the pointer.(2) Undo the mounting-bolts @ of the side handwheel unit and detach it from the actuator. (3) Remove the lock nut of the handwheel and then remove the handwheel. (4) Loosen the bolt © of the bearing holder and then remove the feed shaft @. To assemble the side handwheel, refer to Fig. 8-1 and follow the disassembly procedure in the reverse order.8) Fig. 8-1. View of Side-Handwheel feo sje9. INSTRUCTIONS FOR BELLOWS SEALED TYPE OF CONTROL VALVES The bellows sealed type of control valves differ from other control valves in that the former employ a bellows for seal. This section covers primarily the particular items related to the bellows sealed type of control valves. Note: The bellows seal assembly should be replaced periodically. The frequency of replacements depends on the conditions of use. When handling a mechanism which as a bellows seal assembly, exercise care so that the mechanism is not twisted. Note that the bellows is not highly resistant against torsion. 9.1 Model HLS Control Valves 9.1.1 Structures The handling methods of Model HLS Control Valves differ as the shapes of their ports differ depending on Cv values and on whether they are provided with a teflon insert or not. ‘The structures of typical valves are shown in Figs. 9-1 and 9-2. -67-= —PACKING FLANGE NUT—— e- vex wri) --@ \ VALVE STEM—————— “BELLOWS FLANGE ————P Fig. 9-1. Valve with Fig. 9-2. Valve with Cv 2 6.3 cvs4 ‘and with Teflon Insert9.12 Disassembly and Assembly (1) Detach the actuator from the valve as described in Section 4.1. (2) Loosen the packing flange nut. (3) Loosen the hex nut (1) of the bonnet, using the wrench. (4) Raise the bonnet and remove the gasket (2). Note: When raising the bonnet, press down the stem so that it will not come up together with the bonnet. (5) Remove the hex nut (2) which fixes the extension, using the wrench. Detach the extension together with the stem from the valve body, Note: The stem section has the valve plug, bellows flange, bellows assembly and pin, assembled together. (6) The procedure of this step differs depending on Cv value and presence/absence of the teflon insert as described in Steps (6)-1 and (6)-2. (6-1. For Valves with Cv s 4 (See Fig. 9-1.) © Remove the stem from the extension. ‘© Holding the valve plug using a vice or other tool, remove the pin by using a chisel. Detach the stem from the valve plug by turning the stem counterclockwise, Note: To turn the stem, put back the stem connector onto the stem, (62. For Valves with Cv = 6.3 and with Teflon Insert (See Fig. 9-2.) © Hold the valve plug with vise or other tool, pull out the valve pluguntil the pin comes out of the extension, remove the pin by using a chisel or other tool, and then detach the stem (together with the extension) by turning the stem counterclockwise. Note: To turn the stem, put back the stem connector onto the stem, (7) Remove the gasket and seat ring. (See Section 4.2.) For assembly of the control valve, follow the disassembly procedure in the reverse order. -69-9.2 Model HTS Control Valves 9.2.1 Structures The structure of Model HTS Control Valve is shown in Fig. 9-3. qe PROKING FLANGE NUT o> HEX NUT(2) - 2a) a PACKING FLANGE se.ions ruance oJ O-RING (HGH renperaTiRE Sevier valves AVE Nd OPRING) sten-————*] BELLOWS SEAT ie GASKET(3) BELLOWS, 88) | 5)—aseery oe Fig. 9-3. Model HTS Control Valve -70-9.2.2 Disassembly and Assembly (1) Detach the actuator from the valve as described in Section 4.1. (2) Loosen the packing flange nut. (3) Loosen the hex nut (1) of the bonnet, using the wrench. (4) Raise the bonnet and remove the gasket (3). Note: When raising the bonnet, press down the stem so that it will not come up together with the bonnet. (S) Remove the hex nut (2) which fixes the bellows flange and bellows seat. Note: When loosening the nut, hold stationary the bellows seat so that no un- reasonably large torsion is applied to the bellows, which is not highly resistant against torsion. (6) Remove the bellows flange and gasket (4). Note: The bellows seat can be readily detached by lightly hitting its top. (The most effective method is to hit it by passing a pipe onto the stem.) (7) Remove the hex nut (3) which fixes the extension, by using a wrench. Detach the extension from the valve body. (8) Remove the gasket (1), guide ring and stern, together. Note: The stem section has the valve plug, bellows seat, bellows assembly and pin, assembled together. (9) Remove the gasket (2). (10) Holding the valve plug with a vise or other tool, remove the pin by using a chisel. Detach the stem from the valve plug by turning the stem counterclockwise. Note: To turn the stem, put back the stem connector onto the stem. For assembly of the control valve, follow the disassembly procedure in the reverse order. “ae10. TROUBLESHOOTING This section covers the symptoms, causes and remedies of most probable types of troubles. Parts may be required to be replaced depending on the type of trouble. For further troubles, please order your Yamatake Corporation agent for repair. Table 10-1. Troubleshooting ‘Symptom Cause and Remedy Unstable valve operation © Valve hunts when almost fully closed. © Air supply pressure Is unstable. ‘© ‘Signal pressure is unstable, | Valve hunts even when | © Cvvalue is too large. Reduce Cy value. For a single seat valve, the valve is installed in the reverse flow direction. Large air consuming equipment is hooked up to the same air supply line. (Check that the air supply capacity, piping capacity and restriction capacity ate appropriate. ‘Supply air pressure regulator is inadequate or not operating properly. Controller is not properly tuned. Properly tune the controller (properly set the propor- tional band and other parameters). ‘Check that the controller output does not change abnormally. Hunting of output of positioner itself. © Vaive vibrates (generate | noise) at any position of valve plug. Valve vibrates (generate Roise) only when valve plug is set ata certain Position. signal pressures, ‘Check and repair or replace the positioner. Being affected by pressure change of process fuid as ower ofthe actuator is insufficient. Replace the actuator with a larger one. Vibration of valve Piping is vibrating. Securely fix the piping. Check for other sources of vibration. ‘Worn valve plug or guides. Check the parts and replace them as required. Check for change in process fluid flow conditions (change in restriction orifice, Cv value, etc.) ‘Check for change in plug configuration (change in flow control characteristics.) 4 J “72.‘Symptom ‘Cause and Remady ‘Sluggish valve operation or inoperative valve Fluid leak from gland section © Airleak from piping © Airleak from actuator ‘© Foreign matter entrapped in guide section of valve plug ‘@ Aged and hardened gland packing, causing increased hysteresis ‘© Maifunctioning positioner (Check the positioner by operating It directly on an air Supply known to be operating normally.) © Check for loose packing flange. © Check for insufficient grease. ‘© Check for damaged valve shaft. Liquid leak from gasket | section ‘© Check for loose nuts of bonnet. © Check for defective gasket (deformed or damaged). Even when valve plug is in closed position, large flow | leaks to downstream side. © Airleak at actuator section | © Fortrial, apply the air supply pressure or atmospheric | pressure to the actuator. (Check the air supply source and positioner) | ‘© Check whether the valve plug is actually in the closed position or not. (Check the valve plug tft) ‘¢ Check the plug seat ring for corrosion and erosion. ‘© Check the guide sections for binding, 7311. RECOMMENDED SPARE PARTS Itismost recommendable to replace the following parts when servicing the control valve. © Valve Body Be sure to replace the following parts with fresh ones whenever the valve body is disassembled: © Gland packing © Gaskets Actuator Replace the following parts at every 5 years or thereabout. © Diaphragm © Bushing © Cap © Seal washer © Rod seal Oftthe bellows sealed type of control valves, the bellows seal assembly* must be replaced periodically. The period of replacement depends on temperature, pressure and other conditions of use. typical service longevity of the bellows assembly is 10,000 vertical stroke cycles, * The bellows seal assembly has the seal bellows and valve stem (including the bellows seat) assembled together. Please mention the parts name and the product number indicated on the name plate when ordering those spare parts. “74.Document Number = Document Name : Date : Issued / Edited by : OM2-8113-0201 CV3000 Series Control Valves Model : HLS, HTS, HPS, HLC, HSC, HAV User's Manual Oct. 2000 (Rev. 7) Yamatake Corporation {YWAMATAKE This hasbeen printed on reeled paper reeaereemennn08-16359 OIL BURNING APPARATUS Kk mo RM BR TYPE 15 INSTRUCTION BOOK FUKUOKA SHIPBUILDING CO SHIP No F1273 >RDER TORTOISE ENGINEERING CO., LID. Nishinchata, ty, K a STATON CHECKEDSPEC. TYPE: R SUNFLAME BURNING APPARATUS T tT - 0405] 29— ung, CHIEF 04 1. Ganeral specification 1-1, Sule 1-2. Control system of burner 1-3. Fuel of 1) For coldvstarting 2) For usua-ly calorific value viscosity Electric souee 1} Power eizcuit 2) Control cireit € Alam/Indicator circait 1-5. Ais tenperatore 1-6. The othess 1) Unit 2) Name pate caution plate 3) Painting coloar Boiler specification Type number Pvaporation Stean pressure Stean tenperatare Feed water terperature Furnace pressure F. 0. consurprion 3. Burner specification Type Sumber £.0, combustion capacity Barner moter Rota cup F. 0, pressure P.O. viscosity For atomizing = inclet of equipsent NK Full automatic, ON/OFF s PT control system Marine diesel 211 Marine neavy fuel oi1 low eglorizic value. 40.6 Mi/ke Bp to 380 mn‘/e/50 ACKAOY GORE a6 AGLIGY 60Hz <9 [By dow ACLOOV 60Hlz 1¢4 Do 24v a8 U 3y AC/DC converter} Metric & 32 English English Maneell No, 7.5 a6 7/2 TORTOISE ENGINGERING CO., LID. se — 150 2 Boiler/L ship 15,009 ka/h Desiga 0.93 mea Normal 0168 ea Saturated Lenperatare soe o.y kPa 4,164.19 ka/h FORCED DRAFT ROTARY-CLP ATOMT: 2 get 1,200 ka/t MITSUBISHI ELECTRIC CORE. 5.3 K€ 2P Ineuzation elase ~ "F" “aDex 16h Wor. 0.3 Mea Under 115 mmi/s, Kor. 19 ma'/s Under 252 ané/e4 5 6. Forced draft fan 1 ° Fuel of1 pump unit Type capacity Delivery pressure Suction pressure Prime mover Primary air fan OAL heats Fuel Type Model Wo. capacity Static pressure Prine mover ‘Type Mode Ho: capacity (Secondary aiz fan) Static pressure prime mover type Model No. Heating temperature Steam pressure Heating surface area Heating capacity Steam consumption Accessories |. pressure adj Modal to. witcing oll strainer ype Bore & mesh equipment 2 sets TROCHOLDAL GEAR TYPE NIPPON G-ROTAR MFG. Co., LTD. ‘TOb-N320H-08 2,300 ka/h ove MPa, 0 = 0.03 Mpa NIDEC POWER MOTOR CORP. 2.2 EN 4P Insulation class TURBO BLOWER TYPE ose - 2aLN 24 wms/nin 7.8 ke MITSUBISHI ELECTRIC CORP. 7.5 kW 2P Ingulation class = "F 1Pq4 1 set ‘TURBO FAN TYPE ost - 265 265 nd /min 3.4 kPa NESHISHIBA ELECTRIC co., LID. 30 kw 2? Insulation class = "e" 1paq 1 set STEAK HEATING TYPE, AALBORG IND. K.R. SUNROD OTL HEATER xLv90-200 (DP=10) 6 - wow Max. 0.88 MPa 3.76 me 1,600 kg/h 110 kg/h Air & Drain valve 1 set Relief valve 1 set Control equipment (AIT-U/V type) 1 Set 1 see Eosw (25a) 1 set 18 10K 328 1 set DUPLEX BASKET SCREEN & FLANGE TYPE JIS 10K 40A & 60meeh10. Diesel ail punp unit fer 1G. BNR. (Pilot burning pump) Type Capacity & Del. pressure Prime mover 11, Thermostat « pressure switch Themnostet Pressure svitch 12. Burner accessories 12-1, F.0. solenoid valve Main P.0. solenoid valve D.0. solenoid valve 12-2. F.0. flow regulator § meter ‘TROCHCIDAL GEAR TYPE GFH-VSL 270 kg/h & 0.7 wpa NIDEC POWER MOTOR CORP. 0.8 kW 2P Insulation class DANFOSS €O., ETD. BPS 81 DANFOSS CO., LTD. EPS — 35 \Assenbly to burner) Mx - isms BVZ10B 4.58 No. 45 & vzo - 20/20 12-3. Ignition equipment (Diesel oil pilct burnez) Medel No. 6 Capacity Ignition burner seleneid valve Ignition transformer 12-4. Air pressure switch Model No. 12-5. F.0. pressure gauge 12-6. Suener hinge-Lock switch 12-7. Flame-oye Medel Ne. 12-8, Adz/OLL flow control motor Capacity 12-9, Junction box PUR-255 & 10 kg/h (Reemizer = 36/60") By219B 4.53 15,000 (EBIMO52=) Dues Low-50 av sa" x 6bex 1, FB-01 tea 5) NISSYC INSTRUMENT CO., en-LoinpcezR 20W / 160"~ 325 / 1.23 Sem Wich manu. switen 13. Steam pressure transmitter © controller 13-2, Controller for BNR, ON/OFF/PI cont-rol Medei No. 13-2. STM. press. cransmitter Model No. 14. Burner control panel syetem YROTARE MONYWELL CO., 19D. €312cA000500 DANFOSS €O., 17D. EMP 2 08462109, For deip proof system See “CABLE 1" about indicator and alarms 15. Spare parts & teols see Nore s+ See "TABLE 2" about setting value of pressure 6 temperature Soe “LIST OF SPARES § TOOLS” Page = 6) 1. sMea oe pag (Page = 7) set set Pics Pees Lec set set Bice Pica Pie set set set Set12939% TABLE INDICATOR AND ALARMS [BURNER TRIP] EX, TERNAL cREN (PF. 0. cory] THPTCATOR POR IND./AEARM Fource fallure on = ar = ‘Start-position abnormal oR = sr = Furnace abnormal (Fiane=eye) otk 7 Sera Mis-ignition/Flane failure oR 2 = = ‘Bumer motor Stop _ on 2 =r = F.D. fan stop/Az press. Low oR a aaa = F.0. temperature low oR a <1 F.0. temperature high Alazm Perec o*2 EER. DPM. Level too Low + = "trip total alam (i mark) ok = s abnor. total alarm (2 marki = = ‘DRM. level high alarm 7 ‘DRM. level iow alarm 7 ‘ST-BY F.0. pump start_alare 7 2 3 Feed water pump stop = e a Boures = 2 zi Thermostat by-pass . Burnes stand-by = : BUEner=auto. = 2 .0. flow manual control = Fire (eu. running) = 3.0. miacng = [Space F.0. panp stand-by = You F.0. pump sunning = = 2 Wo.2 F.0. pimp cumming 2 = 2 Nowi Feed water punp cunning = = No.2 Feed weter pump cunning = = Enezgency stop ew. teminal oR = 2 or wore te OR mark = Manual reset, Abnormal = b contact, Running = a contact oti/ot2 mark = Conmon Contact for burner trip/abnormal alarm. STARTER TT CAPACITY x Senn A, Burner Rotor z Ts kw x 2] 2.8 3 Forced draft fan 1 30k x oP | a8 = Primary air fan a 7.5 kw x 2P| 12.6 i Fuel off pup 2 Bz kwx ar] 44 3.5 Diesel of] pump (76. BNR. pump) T 0.4 kw x 0.8 1 Feed water pump 2 15 kW x 2a 25TABLE _SUITING VAUJE OF PRESSURE_AND THMPERATURR, 1. Setting value of oil pressure. (a) 2, Setting value of oll temperature. | Steet ase n237 | P.0. pressure adj. valve 0.3 “T MARE Trex NODEL ne] SETTING TEMP ADJUSTING RANGE (Ns. crap! (atest /s00 ) | RASGR | DIFF vei2 | wim. andet thermometer - Sus oy za01 | trarmo-coutrol valve jowris | 5 120 os Thermostat For oa Roz | UNE =.0. pump concrot _|_BPS"#E L pany | Hisnostat Zor iow Peer so i The Pleas Thermostat for aah Setting value of press. sn./contrelle: pe (4) is depending on the off quality used onboard. fe adjust the all temp. on the list con aot (alarm aio firming actual conbestion status. e. (Abe = kPa, OL1/STM, = MPa} ROOSTING FAW L i] Ives ones we.| serzine eri Rance | DIFF. oF Prinary air press, switch | oK-50 0.25 - feat 4.9 OFF R712 | vecondazy air press. evicch| —* . . 7 0.98) 7 | FO. press. low nnn OFF e aan ier stand-by pump stact_| 3-35 0.2 Pee feet 2717 | sum. press. control csizs [73.6 icra tene2}] (eR. ox/0FF/e: contzor) | (4~20rR) [CONTROL POINT -worR- thermostat & pressure transmitter With none place.20h a on Aun seeasarog fvgiye jain EATING sm DRAIN OT ws #0, 1ayour sm, 18 J18 10K 924 118 10K 284 uo ame are RUS YARD WORKS Aves BovaK 418 10K 264 FLORETS STRATEN [ERFLNE CHT ot [RO WSO RS Fn ETT A a NT Bosss FlOVRETURN : JI 10K 184 era t Me To He CoaETE — LP E Ge — Feta Grr Bret TNO sig ioe 18 Lag Ne vale ——[SMFLawe- [fuga — foes, on So, wave foueoss [veins [Pr FRESE Gale [Deis 0 ao CUMATRRGEEtCepti oot oce 0, PLONETER——[xaat-weve0 | aa-2E [re | abmoosT7T (Con) ARES hepa Resse tale — fis NEE) Ring svornt SOc PRER, oy, VALVE aNTH Cl Pot FRESSVAE GAUGE a) OTA SUNRLANE GO| 1 |aets | SETA BUOY COMREETON|SORPLANE-CO,—[T_[UeTatam_[F-5[FRESSVRE-caUGE — lois Wo 0, FOB ARGRATOR_|SHNFL AE co 1_Ta-te_[aeoo ae TL Poe ReSSIRE GAUGE a eit a Te TATE et — + {ff — — — STM-TRAGE MUST BE DONE FOR ALL PIPING LINE, ee Soames ee Ss ae eennnee anetett oo LIME, ARDMORE STRAINER [SIRF Yene— [wb SECOWT WANES —TSUNFLME C0. TRs is [RE ROUTER Cent ARCO AATTO-OETTC SFL OO [Tea Lo OE 1 LE NTE LE RULE FR a are fe ST Ef Tae PPT eh FERS 0, TAN Gad, FAW|SONFLAWE | [0st-265 [Res aNR, AT¥GE-LOGK S| SWFLANE-CO.—[ 1 373 ANTT-DRIP DEVICE —|SINFLANE CO 11S] aces wr RARY AU aM [SUNFLAG-co,—[ [055-2 [4 70-PLOW vey TaE [WSO 7 | TYOWCTYPE [WTR HOM TEL HAFOSS 1 FD WATER PUMP. 2 [R407 | FLAME EYE [SUNFLANE CO. | [CdS fRTIP [20 AIR PRESS, SWITCH DUNES ROTARY-CUP BURNER BUREN WID-BOK | SUNFLaME-co [16 [eae TesaSFORMER [Sane o—[- 1 JeBTOecr [ar nt_Ark PRESS. VOTER DGS CIErs0 FLOW-SHEET TONG TOU eR UATF[SINFLIME co [I [eva- POA [a0t [NEE wOTOR——WTBUBISHE_F [i uv 2F [oo [ALR LEVEL SW, [SUR ANE [1 O=S0+ ay I+ hed +0>+5-h TNOTRIOR- HO [SINFLIWE 9, #101] _SOLEWID- ALTE TAMFRS TEE GR, FO TAIT | iPron GxOTAR| 2 [TOP-NGR] RO ST STRATEN eae Toa ar, aR mena 2-0] OT |TEW, SOTHO TE [NPIS Jar eT [0 PS Lo) RE TEE ie-a2o |g)" GMFR- 1576 ROTARY fF OWT TSU} TRS a ae Tae UOsTAT (ONT DUIOGS THE ete GRIER CONTGL Fane SWFLAME Ca 68 00 oun WOON RTAR| [area Po [TaemwstaT area) [uWTORS PE ox) SUNFLAME GO,, LTD. IME OF PARTS TANK a Ty]RENARAG| Ne, [uae oP PaRTs —_puncen & Ty] REMARAG| No, [SME OF PARTS. wuezR G Ty REMARAS| wens 5 a eala ses) em | na [eel ee Pe ee ater boy DLA1070 0 250, 200 prosary aig { 150 At FLO IMs seersees JIB 10K 204 ‘Dt FO, RETURN. 5. JIS 10K 164 [PRESSURE GAUGE Bag PHESSURE GAUGE EAR SUNFLAME CO, FIRZOIL RATIO-DEVICE BOUL 00,-WTX, SOL, VALVE Bos soy 7 mite TATE. 0, SOL. VALVE 2aRe Té, BNR, SOU. VACVE Bu 3 wee AF 947 Ky TNT ATOM gn, OFT SMM E SUNFLAME CO, PIPING HEATER en3 NAME OF PARTS: a a ix WlsToey i * ROTARY-GUP BURNER DIMENSION DRAWING OF BURNER WIND-BOX SUNFLAME CO,, LTD, Ree DY++ NOTE ## ‘A 77. FO, PUMP CONTROL AT BNR. STAND-BY ca ea) : (ha tee =a) Foe Sir PHEON TRAE wo Am the Pun -FeehRE-(OTON Su n> i AH Sez | NO BURNER CONTROL FLOW biASRAR DATE, ae Punte—hABNORMAL #41 ABNORMAL 42 SOURCE PATLUBE, aor B. "BAN Stop, AT BNR, OPERATION SW." OFF": TO #4 ABNORMAL TO #5 BLA. DRM, PRESS. HIGH 1 TO +6 TO #4, 05 8 46R101 beavis eIsToRt PLT AA VE aes NOE THE aR @ ci Sin | STR - 0} i zo oer @ roe) Ga”) a CCRT PREF) NTE mi a Pa Bw] OF") MOA) Sr) om sor wan, ST oe — rH ma ®R) wea mare | sr. aware | san manzzee Ht OFF on vaNu, a AUTO, [~4 a r | g sa wate ied | | | TST RESET tt WY Pie BURNER PROGRAMABLE CONTROLLER : SN wee couns Ff 18 7 source wit Ge UNIT IN URIT oT WET 0 | fan 8 ‘x0 peer eeepc 7 23 ¢ f . am ea ol ped area TT | a ae be et We = vans | crust | wae | 32te | ocees |obzet | otzax Losear ee aeons. a Pare [ae saa FTO] FOF rT Wy sac 7, Hy Cra ne STR De eT Tee i cana: perme | eo | MEA ee at ae To FP RAE TOT ovrcse | eve rove como, H - Tae — roiatk sec ei ST) ORT PT ww |b renee] 18 [| OSS Tay fs GARR CVG TT Tsai € Tyi0-5 psera |b Leer Sram (UN) eC 1A) ace. woo Ty [a [RR RE © [1 | Mae nraeea ate Foi. caegT (tary THEORET pans | en 7 FEOF ET —— Ta, \ @eoa | un) ie C1) B HAE Te ha a TS] mp k mrss fe eee TT COTE — faa FOF ceeTT — OM To Fs 39 m eK TD . Me agra ae - Se -00s2en ea? | cet | amuos-ser, Twn eee | sr, iby a Heaton Son ee ee a ae a mon | tee | 7ST TEC ees, tof [Pes af [manent Tekst | Ee Le e [AgMReGRe : ee Te Fi ae LTTE OPTI § ace coe.) 7 3 FESS, DOHDL TTT ie en ae 1 |ocar eur ae oe Sse canny [a | anes vgungamaet TE Re gama |v | : rat re 2 fo | EE wast LPP TE i ; RD a [Bh the tone. Ta 5 ie meee |e (ata) pr | tense | 8 fT Baw wD eum [3 [1 [wer 1a | Ra LP 7 Te CEE wer an) [ir tea | | i . : ie ) ST HESS, oo, Te Fae ye ETT) We Fae i ae ‘ it ca, a rte] 2 | SREDMD & a ies] 2 mn Oe Se TIE LN RE eis 7 iis wes [yam [sla oT | gee i wi Fg imearae levels ete STN ET Teoanae2 | il RRC BOTOR STARTER 8 sets yea) 11 Mh teat WONTAL URGE ORDER convoy sue BURNER CONTROL PANEL Maney: St, ff o8ee i we eat tren |g AE OUT-LINE Fea SERB £ "a-a SCALE A K- + WO BH il sliacleeetli TanTION OFF coe | ae : erm ie ! Ter fa ti PRE EEE o*7h |“ Weezs [gS MER-4664A 1 we [or [a fs a ii Sen ma 8 Ee SUNFL AME 60, LTD, Tate oF rT Tas ATES We oF ms [URED FOE eM wen nN vie ew * 3 B35 ee e [a # + eh Rteae 2uUASOURCE ACd40V 60Hz 36 ee x Y 2 4% p ear __gIaP : tts sn 1S (Raga) £4 catia RQ ee One ki (R104) OF ity sg 15 (5) tT umn t, wer | oa are ea - o) ei o==(aues)— 4 | rae , ioace = pa Dv neon) i jo le Z 5: st J) sano 4, B - Tooho 8B V3 BURNER MOTOR ia Seats eseeeSEECCLEEE bas -— | hore he [hae 26 Bey ghoT eT sop TOE HID | 1 Fo OP ois is —_ 318 5 whee an | Mh Sve Z = 3 - | Lip st soe WHE ION | sn rome . a x DRAFT CAM oy ae Ee oo fon fete. ris oon (a — RET 2 gt p- ~ soo 0 v4 QiL PUMP 29 - a Lo “CONTROL WITOR eS aay eet 7 AL MOTEL : a aH sieh if 30 - pte ge E- 88 None F,0. PUMP ae oe a) a | LeU Tt 8 pe | ese - 1 B [gr ee NG 7 I i F- Pee SNe SB YB PRIMBRY ATR FAN ay am | de Fy sy Ge fer S ; 33 - rz Lee 4 fe Se 4 7 a 3 Lit _igrge i | i SP guy : ~—_—.I=% i — STH, 155, ae s ot TY? No, FEED WATER puMP oa teenie iy - O- eT MESS ean een? 8 KH (R110) 35 - MB wt one “wrt 2 to swuret 96 200 + Wie an a E r | one 36 - | Mh i oy CV oH 38 ay Tey coy es a ae my Ye ra 1 Spe eee ees ® on are mT ue anit, ae By 5 x - 3 ts . ry 3 a, ~~ oar 4. ro am, me Fo Flor 1M i oe Bilan eta ra ue ate [0 ote 5 fH95_1y_ ND eves crite mt 8 Gag ppeasaH e “ry _ a cna sant” raed oy —— 5 u a (08) x5 GF due, ee, weve, roo ont 5 hl a 5 Gr?) 8 pe Ree do ew a1 a % zm it a a 1) 10} : See ees oe ea TaT @ emt ELI § au | cee os SN D0 45 - Tame wt 1 B] é 3 roars cai sane | FOR RA Fa u oun id ue {0 es ay | ST 9 = | pag > 8 i le, ar Tg rE Ft wae i o- | ae rT ns an ae ; ee ea sy 10 0 CH "206" FOR HN SOL a 7 2 r? on TH oa te un cara 50 - x at tek FOR 00, PUMP RULE | 13 - as Birt TET vii," coNTFOL gk ars 51m Mog aT ee leh TION EeEEEEEEEEEEEHEEEE gmap] 14 En TH Bi a St. re i! ag oie BURNER CONTROL PANEL 16 - ue a Sree INTERNAL WIRING DIAGRAM wl ® ® wit 0, = 8 - a] OE Gh Ot Oi ae A Fh ORR WHE | sk i | 7 - oH Tome ppl aga a nA | sk | wI6-6-28 MER 4665 - | UH mt eee 8 _ SUNFLAME CO.,LTD, fae a TT : oo ‘ ee wet voy 7 UA8, TRIE RESET Lv FLOR STOP We TEST [SHERWCSTHT BI-PASS me, wT, HRT Ba, Maat, 8" 7.0, FINE AT, ONE 5.9, PINE WAR, SDE iL nea "ar 1, a, OE he, To, None a, oi, LEVEL TO0 LOE sounee tow a a Opry OH FO, PIMP RURHING (RK TO ON ) Fe Ba a 7 Mo,2 F.0, POKP RUNNING (BUN, 70 8 ) PB Rha eae fs (1 20 on) ag 88 eT SE eee o4 By ——7o 100, 10% sar | 101 et [ap 102 0K ae | oT r ie? Peco eee No, 2 FON PONE PURINE (RON, TO ON) No.1 Fo, END 3, Yo.2 POE th, 3, FAN RUMIN 103 uae MOTOR SUNG 104 FIRE (08, BIN) 105 FR, ATE FAN UH, 100 pee ety 107 FTP, LOW 07, SO) 108 C11 oO} 0, TH, LOW aN, TRIP 5.0, FLOW MAN, DE AIR FESS, 10 Coin, Tee TM, FREES, AIOE (Cant Gh OFF cone | rT, one CBm-UP tT cris Eo va i ts, ‘MTEC Cone) se nae Temeeea ar Gs) Zits —? ar - soe oT exit, 5,8, FAN STAET-DLAY fae, STHRT-FsITION AEN SOLENOID YALE Pe yo aro wo "ace" (10) To sre cup "Hoe 102 60) fixe) aod 800 fxs) aot sso! praia) sy aa poe ove o AEH AR “ne Sait soa a0 | soa? pou of BE soa? s04 e prea h ee | es eae | \ hosp 08) a A06@ BOG 7 2B fafie fe] ik | [ana x a ov. or SY ser a 6 = a 8 7 opp ae Bia of PS mee Cavers 2M Bere rox my wl 5 lap a Be are S are ot Base me uae ig eedite Heli O—0 AIS B19 O—~—O BOILER ABNORMAL ALARN { ABNOR, 70 OFF ) ua | B aie ald O—0 81d B14 oo pew LeveL ICE ALAN us | ag 83 0 AIS co Ebay eves Loe Lane Go. (279, 1008) a au Cum t0.08) (TRIP 10 0FF ) (HIGH 10 OFF ) ° N pas (LOH 10 OFF ) a Al6m 316 OEE Si, SOENOD , DL aEnTER SOTREE ec eee git (0), 27 0 TFT og ae AE mes Ha iia crenttaperg ila A2D B20 7 ban ~ aztqae) oH __ij___ aril vee g nee o 2 8 aol os teaZ 9290 as — 5 wea azaB a24 XN A25 gq B25, ui Ed a A26m 826 swinge sTa0-81 Fa, AN STOP sume NTO, THERA PT-FASS FG LON ‘ab, cOMTROL, SPARE F,0.F Sri-a1 51g La, aN) S04, WP) 9,0, MENG sun, yore stor ST-BF FO, START ig ie aU FURNACE ABNORMAL, Mis-LesrTiow FLA FAURE START-HSITION 5 Pata, Fg, Toe. neti aus, om, ive" r0 uaw aus, LL satan rune ‘AM S08 7 DRAWING HISTORY Eas © CHEDHED a WE oF SURNGR CONTROL PANEL. INTERNAL WIRING DIAGRAM 20 SUNFLAME aieH Yo DRAIN BY ee | m0 A>? i i @ Ene & ng MER- 4666-2 ¢0,,_ LTD, yIVAses Ta RH, AD, We," DM, LEVEL IGE ALAA Dm, LEVEL Lon ALAR WL RO, 1/7 OSE W.2 0 A/F Ose an - WOT; Yom wet sic sae LOBE C2 STF) rere ome Ee ae 2 USE (Ho) ST-87 oem, ave Tee has fe) 60 foe me — Ko eo A Tee + OR EL ‘RANSATER ras) fis, an ee Lg st goo a, Hibs, got et 8 my git g verry RA, gett yeh a e, HGH AU : i i / aT eee “tptioiee | rae ste | sae mi te SOce wa} foe ae NL 0 ye se | Me, ROME RORRING [oa ner 8 i Pesaran at 1) 9 rt 1.2 FO FO UNG Fee ee Pa ee ’ Mi [ca |e an [cum che | 2 ai «ail X01 2 SOURCE ACTIOY 60i2 1¢ = 01 No) ane BURNER CONTROL PANEL } MER-4666-bA\ af rwveawat wraine:prasmaw [Eee TEAR aT § E D. wean] Palate’ [tet 9 9'2 DA£12! ttm AgudoV eos 36 get WM Tie FLT FP wu THK [ight a i ad TH] figghy at ae I reece AT 7 aw 7H eC Hh tia =H a PP ETT E TH 22) f aI TRAD TREE TOR 7H an ay See TH ast 7H ae PT eT TT Er} p ul [Gy REE TH] Ba FE oH ag AEF WE PY Tp ait TT wrt 8 tsp ee a TE} wie Pg [SON TITER, 3] aa} per eS oH 7 1 Lins = x 14 uu HIGH TENSION CABLE X z Ecc aan 2 PEC) oS eta a 7 we ve mm 42403 75] NTT TOBE] ye i anes [Mace ett, cht we 13 8 Pp TOT THOT] i T s oe TTP 3s se oye OTe, BT 2 Ty tw Wy AE TROT z =P rT Z Se RT Trp it 3 ae 0 ee TP TDA 2 BIS TH, TTNGE-LOCK A 2 peep ewe Ee) || vee r Bos fe a pit TOOT TITS 22 fab uw wah ; p veh oe fer Lov sry 9b, S007 } a 1 Ta AT RHA) g Ep twee SE TT] au ul z a coos [Pe tar tb ote RTO 7 29 TE] Tah TATE ih BT ousner 2 oy R08) [= I 5 EDT, TOL TE Fe ene wag [PO PIPING ATER air Hi tense TLE Ww, a Pe essere HAE eee oet 5 io — ato 8511 comon 210 — suees air, a1) Fn (aL, 8) me —_bimek te aL 22 CRT OFT 3 OIL ARORA, Lae 313 —C ARORUL TO OFF) Me AE OMe ee ane ewer 3 AE ONLINE Low ane 313 Clits OF Y Ma — 43 = 300 canon Ha — fa. 0. PND RNG Ha — Hos? FAN HNN tek — i= Be canon 3k — ta HED WM INK 843 —— Hh, FRED W,_PUME_RUNKINE rE. Treo @ B® Bemern ShavRMATTIE SoALE CHECKED BF BURNER CONTROL | @™gMER-46072\| r_g| XO |g ke WIRING DiacRam [2 _& t iT say | DRAWN BY N= tO oD SUNFLAME CO,, LTD, a ARN) as P| y- zuma |eRet bY DLA oeseeees TN OD BX veteee Item Specification Indication and Alarm Setting value of Pressure and Temperature - Oil burner and Accessories 1, Outline of Burner 2. Burner Control system 3. Control Equipment (3-1, ~6) - Preparation before Operation A, Inspection before burner operation B. Initial Operation (1~s) C. Operation Procedures and Caution Items Operation A. Manual Operation (1~8) B. Automatic Operation (1~4) , Ignition Burner - Fugires (AA) 1 setGENERAL DESCRIPTION PETRO rotary Cup Burners, fig 1, are mounted on hinges and can easily be retracted and swung out without disconnection air, oil or electric supplies. In open burner position there is full access to all interior burner parts for inspection and maintenance. The burner secondary air register and flame stabilizer are made of steel plate and no refractory are incorporated in the design. The register is made in sections and can be removed via the burner front door. For multi-burner installations the burners can be provided with automatic shutters. These shutters close the primary air housing when one burner is retracted thus permitting shut-down and maintenance of one burner whilst other burners are firing The burners can be supplied for horizontal or vertical downshot firing. ‘The fuel oil film leaving the rotary cup lip is atomized by means of primary air at the pressure of 12~15 kPa under balance draught conditions. At positive furnace pressure the primary air pressure must be increased accordingly. The primary air quantity amounts to approximately 7% of the total full load air quantity required for combustion. The remainder, 93%, is supplied as secondary air at lower pressure via the burner secondary air register. Required secondary air pressure under balanced draught conditions is varying from 1.5’ to 3.5 kPa depending on factors as burners size, type of fuel oil, furnace dimensions and load etc... Basic turndown range is approximately 4:1 for small burners (R9 - R15) and up to 8:1 4 10:1 for large burners (R25 - R40).The burner is designed to take all grades of fuel oil. Heavy fuel oi] must be preheated to a viscosity of 3 ~ 4°C Engler (16 ~ 30 centistokes, 75 ~ 120 § R 1) at the burner. Under certain conditions the burner will accept oil up to 12°C Engler. To ensure safe light-up the oil in the burner must be kept warm during shutdown periods. For this purpose a small amount of hot oil is circulated through a separate drilling in the burner oil control valve and fed via the burner oil return line into the main oil return line. The flexible oil tube and the oil tube to the oil distributor are kept warm by a low-voltage electric heating cable. Automatic ignition is normally provided by a built-in gas-electric igniter but on special order the burner can be equipped with a diesel-electric ignition arrangement. PETRO Rotary Burner is usually supplied with PETRO standard burner logic system PETROPILOI for fully automatic operation and modulating control of the burner output in relation to the boiler load. PETROPILOT standard unit includes programming relay for automatic start up, normal running and shutdown of the burner unit. It is further equipped with a photocell amplifier and a separate flame scanner head with photo resistor. A built in electronic capacity control regulator PAR governs the burner modulating control motor. PETROPILOT and PER are further described in a separate instruction **Date Sheet 1: Burner capacities, air volumes and pressures **Data Sheet 2 : Dimensions of pipe connections **Date Sheet 3 : Burner main dimensionsIL. DETAILED DESCRIPTION A, BURNER 1, Rotary unit - fig 2 ~ 3 The burner main shaft (1) is with high precision fabricated of a single piece of solid steel. The shaft is supported by two single row radial type ball bearings (2) in a bearing housing (3) made of steel. The front bearing is locked on the shaft by a retaining rang (4) and in the housing by the front bearing cover (5). To allow for free temperature expansion of the main shaft there is a play between the rear bearing and the rear bearing cover (6). An O-ring (7) in the housing prevents rotation of the rear bearing outer ring. The burner is delivered with the bearings filled with a high quality, high temperature grease. For regular lubrication the front and rear bearing covers are provided with lubrication nipples (8) with extension tubes (9) and (10) respectively. Access to the front lubrication nipple is provided by a threaded plug (11) in the primary alr tube. A certain amount of high temperature grease and a suitable grease gun are delivered with the burner. The complete bearing housing is mounted in the center of the burner primary air tube (12). The housing front end is supported by three centering screws (13) and the rear end by the housing cover (14) which is locked with four screws (15) with lock washers (16). The centering screws (13) provide for easy centering of the bearing housing in relation to the primary air tube. After centering, two of the centering screws are locked by set screws (17). The burner rotary cup consists of a hub (18) with hub cover (19) of light alloy and a rotary cup mantle (20) made of hard chromium plated mild steel. Hub, hub cover and mantle are held together by a number of screws (21) with locking washers (22) Between the hus and the hub cover is an O-ring (23) 3The rotary cup is mounted on the tapered front end of the main shaft. The cup is held in position by a key (24), an end disc (25) and a locking bolt (26). For safe locking the thread in the main shaft is provided with a locking Heli-Coil insert (27). Between the locking bolt and the end disc there is a spacing washer (28). The rotary cup hub is provided with a slotted sleeve (29) and a number of radial drillings whose main function is to give the oil rotation and an even distribution over the inner mantle surface. In the rotary cup hub is further a number of axial drillings for transport of primary air to the centre of the rotary cup for cooling and cleaning during burner operation. This cooling air is distributed evenly into the cup by means of a deflector disc (30) of heat resistant stainless steel. The deflector disc is mounted to the end of the locking bolt (26) and held in position by a screw (31) with lock washer (32). The rear bearing cover (6) is fastened by four screws (33) with lock washers (34). Yhe oi] distrioutor (35) is mounted with four screws (36) and lock washers (37) concentrically outside the front end of the main shaft. These screws (36) also hold the front bearing cover (5) in position. To facilitate removal of the oil distributor the bearing cover is provided with another two counter-sunk screws (38) holding the cover in position when the screw (36) are removed. Distances between the rear end of the oil distributor and the bearing cover respective the inner tube of the ofl distributor and the main shaft permit passage of primary air to the centre of the rotary cup. A narrow annulus between the oil distributor outer tube and the rotary cup hub cover provides for the passage of a small amount of primary air into the hub. This air stream prevents fuel oil leakage from the rotary cup rear end.Fuel oil is supplied to the oil distributor through the fuel oi] tube (39) which is inserted in a connection sleeve with double O-ring packing (40) on the oil distributor. The rear end of the fuel oil tube is screwed into the oil connection head (41) which is bolted to the outside of the primary air tube end flange with two screws (43) with lock washers (44). The cil connection head is further provided with @ screwed plug (42) for cleaning. The burner flexible oil tube (45} is connected to the oil connection head. A built in hydraulic lock in the oil distributor prevents oil spillage when vertical burners are stopped or swung up. The burner primary air nozzle (46) is mounted concentrically around the rotary cup to the front end of the primary air tube and held in position by means of four screws (47) with locking prisms (48). This arrangement provides for easy adjustment of the axial position of the nozzle as well as safe locking. The front end of the nozzle should normally be positioned slightly upstream of the front end of the rotary cup, see fig 21. A number of curved vanes in the primary air nozzle provides for rotation of the primary air leaving the nozzle. This rotation should be in due opposite direction to the rotation of the rotary cup. The nozzle is further provided with a distance sleeve (49) held in position by screws (50) with lock washers (51). The air flow between the sleeve (49) and the rotary cup is reduced by a restriction ring (52) which is screwed to a flange on the rotary cup mantle with screw (53) and lock washers (54). The rear end of the main shaft is provided with a pulley (55) for Poly-V belt (56). The pulley is held in position by a key (57) and a set screw (58).The rotary cup motor (39) is flanged and bolted with bolts (60) and washers (61) to a combined motor bracket and belt shield (62) cast in light alloy. The motor bracket is mounted by four screws (63) with lock washers (64) to the rear flanged end of the primary air tube. Oblong bolt holes in the motor bracket provide for easy adjustment of the belt tension. The main shaft belt pulley, grease nipple etc are covered by a cover (65) of light alloy screwed on to the motor bracket with two screws (66). The motor pulley (67) is balanced and held in position on the motor shaft by a key (68) and a set screw (69). A sponge rubber packing (70) prevents primary air leakage between the primary air tube and the burner front door. 2. Front door and mounting - fig 4 The rotary unit is mounted in a spooked bracket (191) which is bolted to the inside of the burner front door (102) by 6 ~ 8 bolts (103) in such a way that the rotary unit can be moved axially (forwards and backwards). For this purpose the spooked bracket has three rollers (ball bearings) (104) in each end. These rollers are mounted on exocentric shafts (105) that can be locked in the bracket by lock nuts (106) and lock washers (107). The rollers are fixed on the shafts by retaining rings (108). By loosening the lock nuts and turning the exocentric shafts the rotary unit can be centered and a possible play eliminated. A pair of quide rails and a quide roller (109) prevent rotetion of the rotary unit around its axle. The guide roller consists of a ball bearing mounted on a guide pin (110) screwed into the side of the primary air tube and locked in position by a plastic friction plug (111). The guide roller is secured to the guide pin by a retaining ring (112).The rotary unit is locked in forward or retracted position by a spring loaded locking pin (113) This pin will fit into holes in the side of the primary air tube and lock the rotary unit in both forward and retracted position. In unlocked position the other end of the locking pin is locking the burner front door so that it cannot be opened before the rotary unit is fully retracted and locked in retracted position. The locking pin is maneuvered by 4 handle from the outside of the burner front door. The burner front door (102) is cast of Light alloy and provided with a sponge rubber packing (114) to ensure airtight closing of the burner wind box. The burner front door is locked by locking levers (115). The door is hinge mounted by two hinged arms (116) with a common hinge pin (117) mounted to the front of the burner wind box. Burners for vertical downshot firing are provided with two adjustable heavy springs balancing the bulk of the combined weight of the rotary unit and the burner front door thus making it possible for one man to swing up the burner easily, see fig 5. The hinge arrangement incorporates a shield plate to prevent damage caused by possible spring breakage. Vertical downshot burners are further equipped with a lecking arrangement for locking the front door in swung up position and a pneumatic or hydraulic cylinder for easy retraction of the rotary unit, see fig 20. A limit switch prevents burner stact or operation when the burner is in retracted or swung up position. Burner wind boxes The burner wind box, fig 1, is designed to accept primary and secondary air from separately mounted fans. The wind box is fabricated of medium gauge steel plate. A built in fixed section of the burner primary air housing forms an enclosed partition inside the wind box front.The primary air inlet is alter-natively located to the wind box front or to the side opposite the secondary air inlet. The primary air inlet is provided with a manual shut-off damper This damper shall normally be in the fully open position when the burner is firing. The wind box mounting flange is bolted to the boiler front piate. The mounting flange has a central aperture for the burner secondary air register which is held in position by bolted clamps. Burner and wind box arrangements are supplied as standard with primary and secondary air inlets in 3.00, 6.00, 9.00 and 12.00 o’clock directions. Wind boxes for intermediate air inlet directions can be supplied to special order. The burner secondary air damper is usually bolted directly onto the wind box secondary air inlet flange. The damper design includes interconnected, contra-rotating damper leaves. Ball bearings and aerodynamic balancing provides for exact and low frictional damper operation. Connection of primary and secondary air ducts to the wind box via flexible bellows prevents excessive material stresses and in severe cases possible deformation of wind box or damper arrangements. A removable conical section of burner primary air housing is bolted to the fixed partition inside the wind box. Primary air is fed from the primary air inlet via the primary air housing into air ports in the side of the burner primary air tube. A self-centering sealing ring, fig 7, is bolted to the flanged front end of the primary air housing. In multi-burner installations each burner is provided with automatic spring or weight loaded shutters for automatic closing of the primary air housing when the burner rotary unit is retracted, see fig 1 and 8.These shutters permit 2 shut-off burner to be retracted and swung up for service or maintenance whilst other burners are firing. For a non-operating burner in retracted position the shutters provide protection from thermal stress due to heat radiation and hot combustion gases from other burners. Sufficient cooling of a non-operating burner secondary air register is obtained by feeding a small amount of cooling air through the register. This cooling air quantity amounts to approximately 2 ~ 3% of the rated burner full load secondary air quantity. The wind box design incorporates the igniter which is mounted in the primary air housing and held in position by a guide bushing welded into the side of the housing. Aix to the igniter is supplied from the burner primary air fan. 4. Secondary air register The burner secondary air register, fig 1, is divided in two sections, an inner flame stabilizer and an outer annular section, to feed the bulk of the secondary air into the flame in such a way that proper mixing and stable combustion is obtained. Both sections are provided with a number of adjustable vanes giving the air rotation in opposite direction to the rotary cup. By adjusting the vane angle in the outer register section the flame can be suitably shaped to fit a wide range of furnace configurations. For hot water or steam boilers with water cooled furnace walls the register material is mild steel except for the tapered front end which is made of heat resistant stainless steel. For boilers with refractory furnace walls the entire register is made of heat resistant stainless steel. The vane angle is adjusted by a special tool when the burner is commissioned and should thereafter not be changed.5. Igniters a. Gas electric ignition The gas electric igniter, fig 9, consists of an outer air tube and an inner gas tube mounted in a connection head with threaded gas and air inlets. The gas/air mixture is ignited by a spark from a single ignition Electrode in the centre of the igniter giving 8,000V to earth. ‘The electrode is held in position by an adapter in the connection head. The ignition flame emerges from the igniter in such a way that it passes close to the front of the primary air nozzle. Gas and air are supplied to the igniter via flexible tubes. For proper adjustment of the gas/air ratio manual gas and air control valves are included in the design. The gas should be supplied to the igniter at the pressure of 5 kPa (500 mm WC). Diesel electric ignition The diesel electric igniter, fig 10, consists of a connection head, an outer air tube and an inner diesel oil tube with a small pressure jet nozzle which provides a finely atomized spray of diesel oil ignited by a 10,000V spark struck between two electrodes. The diesel oil throughput is approximately 2 ~ 3 gph (spray angle 60° ) Air and diesel cil are supplied to the igniter via flexible tubes. A manual air control valve is included. The diesel oil should be supplied to the igniter at the pressure of 7 ~ 10 bar. 6. Flame detector The flame detector is as standard equipped with a photo resistor mounted in a head which is connected to a sight tube screwed onto the burner wind box front. The flame detector monitors the flame via the secondary air register, fig Li. 10Burner internal oil system The burner oi1 control valve, fig 12, is mounted on a bracket on the burner wind box. The control valve is provided with flanged connections for the main fuel oil to the rotary cup. There is a separate boring in the valve housing to keep the valve warm by recirculation of hot oil. The burner is provided with two automatic fuel oil shut-off valves, type solenoid valves, or for large burners ball valves with built on pneumatic actuators. For most installations the burners are delivered with rotary sleeve type oil meters. A basic diagram for the burner internal oil ways is shown in fig 13. The total burner valve arrangement is kept warm during shut-down periods by recirculation of a small amount of hot oil. This hot of1 is bled from the main oil inlet close to and upstream of the first automatic shut-off valve and fed via a separate small-bore pipe into the separate drilling in the oil control valve housing and further via the burner return line into the system main return line. This recirculating 011 pipe work should be mounted in close contact with the burner automatic shut-off valves and the oil meter The burner return line is provided with two manual shut-off valves, one of which is drilled to provide an orifice which controls the recirculating flow under normal operating conditions. During a cold start this valve can be opened. From the oil control valve the oil goes through a flexible oil tube to the rotary unit oil connection head and from there it passes via a tube to the oil distributor. During shut-down periods the oil in the flexible tube and the tube in the rotary unit is kept warm by a built-in PIFE insulated low-voltage heating cable. The cable is connected to a low voltage transformer with separate high and low tension windings. Transformer output 2 x 12, 2 x 18 and 2 x 24V, 100VA. wu‘The heating cable maximum effect is 50 VA when connected to 2 x 24v. The heating cable can be switched in continuously without risk for overheating. To prevent oll spillage from a shut-off burner an air pressure controlled spring loaded diaphragm, fig 14, is connected to the burner oil ways downstream of the burner automatic shut-off valves. During normal burner operation the diaphragm is depressed by the primary air pressure. When the burner is shut-off the diaphragm is lifted by the spring pressure and a small amount of oil is drawn out from the oil distributor. This amount of oil compensates for possible volume reduction of the system caused by bending the flexible oil tube when the burner is swung up. 8. Burner air/oil control linkage The burner capacity is normally controlled by a reversible modulating motor. This control motor is mechanically connected to an adjustable aix/oil ratio control device, fig 15, having a main shaft driven by the control motor and connected to the burner secondary air damper by a link rod with snap connection ball joints For control of the oil quantity the ratio control device is equipped with an adjustable cam mounted on the main shaft and connected to the oil control valve linkage by a follower arrangement. The adjustable cam has a number of set screws for adjustment of the air/oil ratio. The air/oil ratio control device can be manually disconnected from the control motor and manually locked in a number of fixed positions with in the burner capacity range. A low fire start interlock switch prevents start on high fire. 12The burner can on special order be supplied with a more sophisticated electric or pneumatic combustion control system including metering of air and oil quantities and regulating one or the other to a preset air/oil ratio. Automatic compensation for barometric pressure and air temperature can be included in the system. Zirconium oxide cell based Oxygen Trim Controller for constant flue gas 02 content operation is also available. 9. Auxiliary burner equipment The burner is delivered as a complete factory assembled unit with wind box, combustion controls and other associated equipment such as primary air pressure switch, secondary air pressure switch, ignition transformer, ignition fuel solenoid valve, low-voltage transformer for heating cable, fuses for heating cable, electric wiring, pipe works etc. All electric equipment is connected to a terminal strip in the burner connection box, fig 16. This connection box is mounted on the burner wind box front. B. FUEL OTL DISTRIBUTION SYSTEM Fig 17 shows a typical oil distribution pipe work layout including pumping and preheating, ring main and pressure control system. The oil pressure upstream of the burner oil control valve should be constant to ensure correct air/oil ratio. Rated fuel oil pressure is 3.0 ~ 4.5 bar depending on burner size, see Data Sheet 1. The fuel oil pressure can be kept constant by means of: . Pressure regulator, eclectic or pneumatic. This type of regulator is independent of with 2 pressure variations in the main return line and keeps a constant pressure independent of the oil throughput. 13b. Pressure reducing valve and pressure relief valve Each burner in the system is provided with a pressure reducing valve and the ring main pressure is controlled by a spring loaded pressure relief valve. A high pressure, 6 ~ 8 bar, in the ring main facilitates the function of the burner pressure reducing valves. IGNITION FURL, DISTRIBUTION 1, Bottled gas system Bottled gas is supplied fron a system as shown in fig 18. Rated gas supply pressure at the igniter is 5 kPa. The gas pressure is maintained by 4 pressure reducing valve connected to the gas bottles by an automatic changeover valve which changes to the other bottle when one is empty. The pressure reducing valve should be sized for a gas flow of at least 6 kg/h. Care should be taken to ensure that full bore is maintained through all pipe bends. All internal burrs should be removed. Before finally connecting the igniter the pipe work should be cleaned by compressed air. Diesel oil system Diesel oil is supplied from a system as shown in fig 19. Rated diesel oil supply pressure to the igniter is 7 ~ 10 bar. Before finally connecting the igniter the pipe work should be flushed out with light diesel oil. Pipe work for bottled gas or diesel oil systems can be made from either copper or steel tube using suitable compression fittings. 14TIL. MOUNTING INSTRUCTIONS The burner main mounting dimensions are shown in Date Seet3. It is recommended that the joint between the wind box mounting flange and the boiler front plate be sealed with a heat resistant packing such as glassfibre or asbestos twine. Flexible bellows for connection of primary and secondary air ducts to the burner wind box prevent excess material stress and possible damage due to heavy duct weights or temperature expansion. Use a short length of Elexible rubber tube for the primary air connection. A flexible bellows of PVC coated glassfibre fabric is recommended for the secondary air connection. The pipe work system comprises a ring main with a pumping and heating unit basically shown in fig 17. The system should be laid to 2 fall to facilitate bleeding and prevent air locking. If necessary automatic de-aerators should be included in the system The pipe work design (layout) should allow free temperature expansion and all burner pipe connections should be protected from excess stress by fixing the pipes with clamps close to the burner. Electric installations should be performed in accordance with current local electric safety regulations. High temperature insulated cables should be used wherever necessary. AV. _PRE-PIRING OF REFRACTORY _ If any plastic refractory, brickwork or refractory castings are included in the boiler design special care should be taken at initial start up to ensure that the refractory gets a proper first heat treatment. The boiler manufacturer instructions should be followed. 15VW. COMMISSIONING INSTRUCTIONS Heavy fuel oil should be preheated to a constant viscosity of 2.5 ~ 4°C (16 ~ 30 est, 75 ~ 120 $ R 1) at the burner entry. The primary air pressure should be 12 ~ 15 kPa depending on burner size, type of fuel etc. Too high primary air pressure will give difficult light-up and unstable flame at low tire. Too low primary air pressure will result in bad fuel oil atomizing and consequently bad combustion. 1. Setting the burner oil and secondary air capacities At nominal oil pressure the burner will have its rated maximum oil capacity when the of1 control valve is in position 10 as indicated by the dial Nominal oil pressure measured upstream of the oi1 control valve is 3.0 bar for burner sizes R-9 ~ R15, 3.5 bar for R-25 and 4.0 bar for R-40. A slight variation may occur due to manufacturing tolerances. The oil throughput should therefore be checked by the burner oil meter. The manual primary air damper should be in wide open position. The control linkage is set up as follows: Disconnect the air/oil ratio control device from the burner control motor and set it manually in the low tire position. Light up the burner and set the burner low fire capacity by adjusting the length of the arms and the Link rod in the oil control valve Linkage. Now move the ratio control device manually to the nigh fire position and check the high fire capacity by the oil meter. The high fire position may need adjustment which is performed by further adjustment of the control valve linkage. When both the low and high fire oll capacities are properly adjusted proceed with adjusting the secondary air control linkage in the same manner as for the oil control linkage until proper low and high fire air capacities are obtained. 16Check by flue gas analyses. After adjusting the linkage low and high fire positions all locknuts should be tightened and the linkage snap connection ball joints secured. By changing the oil pressure a uniform change in oil capacity throughout the entire burner capacity range can be obtained. An increase or decrease in pressure with a certain per cent value will increase or decrease the oil flow by approximately half that value. For example: A 6% increase in pressure will increase the oil flow with 3% over the capacity range. 72, Fine adjustment of the burner oil capacity After setting the low and high fire air/oil ratios by linkage adjustment as described above the ratio for intermediate control linkage positions can be set by the adjustable can in the air/oil ratio control device. The adjustable cam is provided with a number of adjusting screws each holding a cam strip carrier. This carrier is locked in position by a locking screw moving in a slot in the cam disc. The cam is adjusted as follow: First loosen all carrier locking screws. Run the burner in a number of steps from low fire to high fire and check and adjust the air/oil ratio in each step by setting the strip carriers progressively until proper ratio is obtained within the entire capacity range. Check by flue gas analyses. After adjustment the carriers should be locked to the cam disc by the locking screws. If a secondary air pressure or differential pressure regulator is included in the set up the primary air pressure should be set at such a level that the secondary air damper 60% open when the burner is in the full high fixe position As for the oil pressure a change in secondary air pressure with a certain per cent value will change the secondary air flow by approximately half that value. Check after setting the control linkage that all locknuts, setting screw, joints etc are tightened or secured. 18VI._BURNER MAINTENANCE Daily routine 2, Clean oil filter 2. Check oil pressure and temperature. 3. Check furnace pressure and flue gas temperature. 4. Swing out burner and clean the rotary cup as necessary. 5. Check combustion quality. Weekly routine 6. Check tension of burner and air fan belts. 7. Wubricate fan and rotary cup bearings if necessary. 8. Check igniter fuel nozzle and ignition electrodes. 9. Check function of flame detector. 10. Lubricate control linkage if necessary. Special service notes 11. The burner Poly-V belt tension should be adjusted after the first 50 ~ 100 hours burner operating period. ‘ACreate the belt's condition that bends inside 15mm because of pushing it 45 bythe power of 20N when it is set. eet 12. The burner main shaft ball bearings should be lubricated with 4 ~ 5 grams of grease every 1,000 cunning hours. Use Chevron Industrial Grease Heavy or Esso Unirex N3. The daily rotary cup cleaning is performed without removing the cup from the main shaft. It may, however, after a long operating period be necessary to remove cup, primary air nozzle and oil distributor from the burner for a more thorough cleaning in some oil dissolving agent such as “white spirit” or similar. The votary cup is mounted on the tapered front end of the main shaft and held in position by an end disc, a spacer and locking bolt. Special tools for removal of the rotary cup are delivered with the burner. 19Dismantling and re-mounting of rotary cup 1. Swing up the burner and remove the cover over the rear end of the main shaft. Lock the main shaft by fitting the appropriate H-configurated tool over the spanner seats on the main shaft pulley and on the burner oi! connection head. 3. Remove the deflector disc in the center of the rotary cup. 4. Remove locking bolt, spacer and end disc. 5. Fit the rotary cup remover over the rotary cup hub and tighten its center screw until the cup comes off the shaft. The rotary cup mantle should not unnecessarily be removed from the cup hub. The mantle is fixed to the hub by 6 ~ 8 screws tightened by a Gynamometric wrench. Uneven tightening of these screws may cause unbalance in the rotary system. Before remounting the rotary cup make sure that the tapered seat in the cup as well as the taper on the main shaft is clean. A thin layer of grease, preferably with molybdenum sulphide, on the shaft taper prevents sticking, thus making next diemantling easier. 1 the rotary cup for some reason has stuck to the main shaft the cup can be removed by heating the cup hub carefully with a small gas torch. Note: The cup must not be heated to a higher temperature than max 150°C Note: Never use tools of steel or other hard material for cleaning the cup. 206. The burner oil distributor can be removed after dismantling of the rotary cup. Use the long hexagon wrench to unscrew its four mounting screw. Thereafter the distributor should be pulled straight out. Clean the distributor in a solvent. Before remounting check and lubricate the O-ring sealing. The burner primary air nozzle should if necessary be removed for cleaning. when remounting check the distance between the nozzle front end and the rotary cup front end. Suitable distance is shown in fig 21. Check the centering of the rotary cup inside the nozzle. In all oil tight, flanged or other connections using O-rings as sealing elements the used O-rings should be replaced by new in case the connection is broken for service or any other reason. Clean the fleme detector from soot, dust ete regularly. Check regularly the function of the heating cable inside the burner flexible oil tube. The proper function of this cable is essential for safe burner start up. Check regularly the function of all automatic burner safety controls such as flame detectors, air pressure switches, oil pressure and temperature switches, boiler thermostats, boiler water level controls etc. 211 2. Type: R . Normal Maintenance We will explain with Fig (4) 1-1 Loosen locking pin (113) towards outside and pull burner assembly. After removal of burner assembly, locking pin is returned and is tightened as set hole of burner body indicated fig (4). 1-2 Loosen 4 Pes of lock lever (115) and open hinge (open 90 degree completely) 1-3 Reverse procedures are done for returning of burner assembly. When you pull main shaft bearing housing We will explain with Fig (2,3 4 4) 2-1 Please proceed above 1-1 and 1-2 2-2 Loosen installation bolt of motor bracket (62) and remove belt (56) then remove motor bracket (62). 2-3 Removal sequences are as follows. Primary air nozzle (46) Deflector (30) Main shaft end dise (25) Rotary cup hub (18) 2-4 Remove two (2) Pes of allen screw (17) among 3 Pcs. And then loosen centering screw (13). 2-5 Remove fuel oil tube (39) and fuel oil connection head (41) 2-6 Remove allen cup screw (15) and pull main shaft housing (3) 2-7 Exactly same procedures will be done for returning. However, Paragraph 2-4, Centering should be carefully done. 22Oil Burner and Accessories 1. Outline of Burner This burner consists of rotary cup, wind box, ignition system and safety control devices for combustion. The fuel oil is led to rotary cup burner and it is spread out inside of rotary cup. By high speed rotation of rotary cup, fuel oil is spread out equally, and it makes very thin oil film from cup edge to 90 degree angle. High speed air from primary air nozzle rotates opposite direction of rotary cup collides into thin oil film and it makes atomization. Secondary alr(air for combustion) is distributed equally by wind box and it is supplied from outside of primary air nozzle for easy mixing of oil particles. Ignition is made by flame of diesel oil pilot burner. Atomization of main burner is done around rotary cup. Therefore, oil pressure is relatively low and atomization is equal. And complete combustion and low load combustion with excess air rate can be done. 2. Burner control system The burner is controlled by two points (ON/OFF) basically. If the burner has proportional control system optionally, it can vary oil flow rate depending on steam pressure. Ignition RIGH OTL RATE on/OFF AND PROPORTIONAL CONTROL Low on < PROP. RANGE —> OFF BOTLER PRESSURE (A-1)3.Control Devices 3-1 3-2 a4 Flame eye (monitoring of combustion) (R407) The flame is monitored by Cds, and safety circuit consists of semi-conductor rectifying circuit. Thermostat (R612) Control use for F.0. pump circulation When oiltemperture is lowered in pipe line during burner stand-by condition, F.0. pump is operated by this thermostat. By circulation of high temperature oil at pipe line, oil temperature is monitored and is maintained at constant temperature. Thermostat (R626) Only for waste o41 combustion use. Same as paare 3-2 4 control W.0. pump. Diesel of1 Solenoid valve (R609) This solenoid valve is opened at certain time from the time of burner stop signal by boiler steampressure and then D.O. pump is started. Feavy oil reamined in pipe line between main solenoid valve (R608) and rotary cup (R234) is replaced to diesel oil. However, this function does not operate when emergency stop and diesel oil use. Oil air flow Control Motor (R408 is not included with ON/OFF specification) This motor is set for rotation of 190 degree. Oil control valve and secondary air damper are connected with control motor and it is stopped at certain position of boiler steam pressure. (High or low combustion) tric, heater which consists of relay at SOE part of oil temperature contE Sensor part is locate! x of oil heater and relay part erature setting device) is locate: control (A-2)value, setting should bs dane=< . sing of screws for relay. Presentation for Operation A. The following items are inspected prior to burner operation. 1. Inspection of pive line end opening / closing of valve for water supply. 2. Inspection electricity and control air for water supply control. 3. Inspection for water level of boiler. 4. Inspection of oil piping compared with flow sheet. a) In case oil flow meter is installed in, please inspect whether Line As correct or not. (Oil flow measurement can be correctly or not} b) Position of Relief Valve is correct or not. (Oil is enough circulated at close position to burner or not) ¢) Position for return line connection is correct or net. (Air can be taken out enough) a) Inspection of heating trace and insulation is complete done or not. (Whether blowing air in engine room may cool off pipe line or not) 3. Inspection of oil quality for service tank. 6. Inspection of opening / closing and leakage for valves oil pipe Line. (fspecially, ignition buener, suction line, air removal and oil leak) B. Initial Operation (including boiler is stopped for a long period of time) 1. In case service tank can not be heated, operation is done by diesel oil. (In case boiler is stopped for a long period of interval, pipe line should be changed over to diesel oil for operation} 2. Please take out air remained in oil pipe line. (When test operation is done after hydraulic test, It is necessary to remove complete water con confirm that oil is reached at level of pump suction) 3. Inspection of wiring for contro! panel and junction box. Inspection of rotating direction of each electric motor. 5. While boiler is at cold condition, burner is operated at low combustion. After boiler is warmed up (Boiler pressure is over ixg/cm2), then it is switched over high combustion.C. Operating Procedures and Cautions Items Burner operation is generally Automatic operation but it can be also operated manually. In this cage, flame detection is done by flame eye and oil burner is cut off at low water condition. But burner cut off by boiler pressure increase will not be one. Please be caution. When ignition is done, solenoid valve switch must be “ON” after confirmation of pilot burner flame. er regardless automatic or manual combustion. In case of proj ional control, “#.0, FLOW CONTROL” vo. as followings “BUR. OPERATION” is “AUTO.” or oil rate can var y turning Gardless whether (1) On “AUTO.” of the vol the rate is VE by steam pressure controller. (2) “of the volume, the rate is manually varied into amypgsition 2 2. In case Two(2) F.O. pumps, please select F.0. pump No.1 or No.2 by control panel. At same time, please confirm valve OPEN/CLOSE for piping system. 3. Before you put on power, please confirm that each switch of control panel is “OFF” position. 4, Kindly OPEN/CLOSE of valves for oil piping system order to use different kind of oil and thermostat by-pass switch (By Pressure switch for lowering of oil temperature) must be set by various oil. {In case diesel oil is used for combustion, thermostat by-pass switch is “ON” position) (B-2)Operation A. Manual operation 1. Main source is turned on after confirmation of every item for operation proparation. 2. please confirm OPEN/CLOSE of valve on each fuel oil supply line for using fuel oil. 3. In case diesel oil used, Oil heater switch (3-QH) is “OFF” position and Thermostat by-pass switch (439) is set at “on” position. (Cancel switch for P.O, temperature low) In case burner is HIGH/LOW combustion control, Oil flow control switch {43-QC) is operated at combustion position after firing of at low combustion. When burner is cold start, Oil flow control switch should be set at “MANU. LOW” position. 5. Burner operation switch (43-B) is set at “MANU.” position and press Ignition manual switch (3-IG) after lighting of Ignition ready lamp (OL). (1t normally takes 3 second for ignition. In case ignition fails for 5 second, turn off switch and investigate cause of faillure.) Pre-purge is set for minimum 30 second by timer (2MPG). 6. After firing of ignition burner, press Oil solenoid valve manual switch (6-M¥) together with pressing of Ignition manual switch. Please release your hand from each switch after firing main burner. made by Oil flow control Sut E changing of loaf. —F 7 + 7-eit-capacte > 8. Change over from diesel oil to heavy fuel oil is made by valve operation during oil burning. Whenever, heavy fuel oil reaches more than half of fuel oil in the pipe line, Oil heater switch (3-QH) is turned “ON”. In case oil temperature exceeds setting value, Thermostat by-pass lamp starts blinking and then turn off Thermostat by-pass switch. In case change over is made from heavy fuel oil to diesel oil, please follow reverse procedures accordingly. 9. For stopping of HiGH/HOW-combustioncontre:-busner, Oli fion-eont rel subteh 43-96}-is-set_st MANS_LoW_pesitier-sad Oil solenoid valve manual switch (3-MV) is pressed “OFF”.Automatic operation Initial operation procedure are same as Para 1 - 3 of manual operation. In case heavy fuel oil is used, Oil heater switch (3-QH) is turned “ON” position and other switches are set at “AUTO.” position and Burner-auto. switch (3-B) is turned “oN” position. Whenever operation condition meets, burner is operated automatically by progress control. (Morever, please see flow-chart details as per enclosed.) 2. Burner auto. switch is “OFF” position for burner stop and it is stopped after completion of post-purge. (Please do not cut off Mein source until completion of post-purge.) 3. Auto.-operation time table for operating procedure 1 4 2 and operated for program control sequence which is listed in the next page. (c-1-b)‘STOP + PRE~PURGE -> IGNITION -> AUTO. COMBUSTION CONTROL -> STOP-PIRE -> POST-PURGE —> STOP ‘START SIGH. PRE-PURGE 1G. TIMING, NOR. RUN. PosT-PURGE OM 38 705 f \, a Oo 0 2D Serer re tee eerie eect t + +—t+ TIME (sec. TIME_(sec.} BURNER (FD. PAN/®. 0. PIMD/ENR MOTOR) Eee ‘AIR DAMPER OPBK_/ CLOSE SIGN. Heer inet TGNITOR SOLENOTD VALVE = am 1.0. PUMP & D.0. PURGE SOLENOID VALVE. VR AG FLANE-WONITOR A FLAME-EYE_ABNORNAL A WARK $1 & TI - D.0. PURGING dose not work after D.0. burning or EM STOP © Tenitor |. Regardless of manual or autonatic operation. ignitor is a iwportant ean Please be aware of electrodes clearance and crack In case crack and removal of vise from electrodes, please replace iL Setting position of electrodes is refered attached drawing DL Stopping signal 1. Burner “OFF” signal by boiler drum pressure. 635 (R702) 2 Burner~auto. switch (43 - B) “OFF” signal on Burner Control Panel 4. Burner emergency shut-off (oR mark) signe! in atached “TABLE 1” of this specification exent Flame-eye abnormal, Wis-ignition and Source E. Abnormal 1. Blane-eye abnormal In cace flame is caught within 25 seconds after burner start from stand-by condition, burner is locked. 2. Wis-ignition In case ignition system become failure, main solenoid valve duse nat operate and ignition system gives alarm Then it stops after post-puree. In case ignition system is normal condition, ignition action is carried out and it gives alarm and stops after post-nuree. (C-2)CAUTIONS FOR HANDLING OF SUNFLAME ROTARY-CUP BURNER §R Type PYIVA Ae) Hye S-TRRVOERBH **In case disel oil is used, heater switch should be turned "OFF" and thermostat by-pass switch [cancell of oil temp.) should be turned “ON”. AR te MOE MM RBAT FDS" REP SATE RAD GME EE) RAYF ER UCL TRL T FEY, **In manual ignition, ignition flame should be inspected visually before solenoid valve switch is turned "ON". FORE CCRATOWIR, A727 yar K-FORERY AR TMB ERIC RURAL Y FE ELTA, **Set temp. of thermostat (adjusted to reading value of thermometer; standard value shows for oil of 3,500 sec. RW. NO. at 38.) WR EM CRW. NO.L 3,500% / 30 EM / iM Rt A Bi KS) Standard | For ehis ship temp. 00 high (burner cut) 150 Wm BR (A-teayh) Be O=d temp. high (alarm) 1450 Ween (ew) Oil heater control : 115T iu Ae : Pomp control (F.0. ciraslarion in tow oll temp.) 7 100T 7 whi (BRL OER) ©. temp. low (alarm) 7 30T BREE (Se #) F.0. temp. too low (burner cat) 30 MER (S-t-Hyh) Heating temp. of tank 80c FrIMR EE ‘*Interval for inspection and maintenance RM Standard] For this ship az weyh ning of rotary cup Bong) aT Maintenance of ignition burner ieek/Twice or nore AP av ay KOFI — w= 0 Cleaning of flame eye glass Weekly PUBS T 4 A i HR Cleaning of strainer screen by =F Cleaning of heater element Env ebay hieSet pressure of F.0. pressure adj. valve MEMS POM HE A 3.0 Kg / oma Adjusting screw of oil flow control valve should not be re-adjusted by ship Flow rate had better be re-adjusted by press. adj It is increased in proportion to pressure. MER B POM MAI RA LR eR ey MEOW MR RSE OME CHoCC ES HEE kin MeL Fv hit RAM E+, - Valve. Aso RQ TYPE: 1.5 mm RIS TYPE ; 1,5 = 2 nm R25 TYPE ; 2-3 mm RAG TYPE; 3 = 4 mn **Purpose and set time of timer BAe — We A A AD EA A ae Please see the caution fir handling of SUNFLAME ROTARY-CUP BURNER installed in the control panel. PMBICMBSN CHVET PYILA- OSB) - AyD NF REB EBSCO R EAL, Before finishing of burner for long interval of boiler running, diesel oil burning must be carried out for replacing of pipe line RL FORRES RAL EET BAK BEM EF fy aA ww WY BA CHEL THON FRE EL TSE b, Electrode set position for ignition burner. mUP hay RO’ y b ft |PETRO ROTARY CUP BURNERS @ OPERATING AND MAINTENANCE INSTRUCTIONS @@ I. GENERAL DESCRIPTION I. DETAILED DESCRIPTION A BURNER L Rotary unit ey Front door aad mounting a Burner wimdboxes a Secondary air register s e Plame detector ™ Burner internal oil system 8. Air/oil control linkage * Auxiliary equipment B. (OM, DISTRIBUTION SYSTEM ©. IGNITION FUEL DISTRIBUTION ca Gas system Pa Diesel oll system ml. MOUNTING INSTRUCTIONS wv. PRE-FIRING OF REFRACTORY ve COMMISSIONING INSTRUCTIONS Pa Setting the burner oil and secondary air capacities a Fine adjustment of the burner oil capacity ve MAINTENANCE INSTRUCTIONS Data Sheets10.4 x 1.6 19.4 X16 25.4 X 1.6 19.4 16 19.5 X 106R812 R252 R242 REDE ROTARY CUP BURNER (\ a | | R731 20 R255—— ' INTERNAL OIL_SYSTEM 21__ ALTERNATIVE POSITION OF R731 R731_DIAPHRAGM HOUSING 20 PROMARY AIR CONNECTION 6A R608 AUTOMATIC SHUT-OFF VALVE _MK25/32 ‘17 PACKING GLANDS Rité TEFLON INS. HEATING CABLE %é__LOW-VOLTAGE TRANSFORMER _100V R255 FLEXIBLE OW TUBE 7 34 OL DISTRIBUTOR’ 25/10 R257_FLOW-METER STRAINER 258/324, %B__OWL TUBE IN ROTARY UNIT 25/40 R243 ORIFICE VALVE 15A 52 BNR. GL CONNECTION HEAD 25/40 R242 _F.0. FROW METER v20-25740 70__ RECIRCULATING Ol PIPE BA R234_ROTARY-CUP 25/40 9 CONTROL ARM. R231_OiL CONTROL VALVE 25/40 Pek OIL PRESS. GAUGE #60 x Vb R230_QUICK CLOSING VALVE 258/328, RBi2_THERMOMETER 0 - 1500, MPR-1220ROTARY CUP BURNER PRIMARY AIR ENTRY GENERAL_ARRANGEMENT 2 BUENER FRONT DOOR ia _DITTO ALTERNATIVE LOCATION 13_HINGES. 2. SECONDARY AIR ENTRY. ik PRIMARY AIR DAMPER 3 FUEL OL ENTRY 3$ SECONDARY AIR DAMPER 6 PRIMARY AR NOZZLE i08_IGNITION BURNER UNT PRIMARY AlR TUBE. R103 BURNER WIND-B0X, 3” PRIMARY_ AIR HOUSING R237_ROTARY-CUP 10__AUTONATIC SHUTTERS R401 BURNER MOTOR 11 SPOOKED BRACKET WITH ROLLERS R501 SECONDARY alk REGISTER, MPR-1220-aROTARY CUP BURNER REAR SECTION R9, 15/25, 40 Gi [LOCK WASHER sr 43 [SEREW [mse [ Te [ALLEN SET SCREW 7 [x a2 PLUG. em EasI) 75 [WaiN SHAFT SELT PULLEY KEY | ci FEL COMME 1 T2_[POLY v-BELT 1 35__| FUEL lL TUBE 7 Ti] MANN SHAFT SELT PULLEY | tacwioe! : Ane aoe Pecans tae ALLEN CAP SCREW 1_[He x S| 69 TALLEN SET SCREW Then thee Hace fi ar [eur Saar? | ALLEN CAP SCREW [M6 a 75-67 [wOToR sHarT orLT SULLY [4 ROUSING COVER 1 66 COUNTER. SUNK ALLEN READ SeREW 17 [HS PRIMARY AR TUBE 7 [cover 1 GREASE NIPPLE EXTENSION 4 64 [LOCK WASHER, a3 [M8 EMS 4 GREASE NPPLE 1 ea_[ scRew oe | HOE NE O-RING 1 [esas | 6? TwoToR BRACKET 3 REAR BEARING COVER 7 Gt [LOCK WASHER 72 AWW SHAFT SEARING ROUSNE | 60_| ALLEN CAP SCREW. <0 MAIN SHAFT BALL BEARNG [1 [ooozronnz 8407 @UANER MOTOR ‘Hs © ie [MAIN SHAET 1 R255 | FLEXIBLE OL TUBE 1 MARK | NANE_OF PARTS [TY] REWARKS [WARK [NAME OF PARTS Ty REMARKS.36 2 1 3:3 11 9 B M5537 19 29 56 24 57 47 4B 18 49 46 30 3 [| | j : al C2 r 1] 5 ‘ iI I 2 53 50 392 5 40 4 58 35 n 23 56 52 St 27:25 28 26 «=R234 ROTARY CUP BURNER FRONT SECTION 9, 15/825, 40 MPR-1220-c 30_T DIFLECTOR BEBE EES Li R234 [ROTARY CUP MANTLE 1 29_[ HUB SLEEVE 1 2_T ALLEN CAP SCREW 16/8 | MS/MG 25 _S1_|LOCK WASHER am ALLEN CAP SCREW T3 M0 x 25 48 | LOCKING PRISM 4 11_[ LUBRICATION PLUG til 460 [O-RING z 3_| MAIN SHAFT BEARING HOUSING | 1 35 [FUEL Ol DISTRIBUTOR: i 2__[MAIN SHAFT BALL BEARING aT COCK WASHER 11th 103 104 101 2 106 107 104 108 105 102 = \L = = \ I es V 16 gh ws® ROTARY CUP BURNER : MOUNTING AND RETRACTION ARRANGEMENT R9, 15 / R25. 40 MPR-1220-d 708] RETANINE RNG ops ENGE PH eter “07 [LOCK WASHER amie ANGE ARN 105] LOCK NUT |e LOCK LEVER a 105 ECCENTRIC SHAFT ste SPONGE RUBBER PACENG [1 17x 04 TROLLER (GALL SEARED &_jenraanee | 73 LOCKING PAN i 03 SCREW 6TH 712 RETAINNG RNG CEE 102 [BURNER FRONT DOOR 8 T_[ PRASTIC FRICTION PLUG 7 101 | SPOOKED BRACKET 6 “10 GUIDE PA haa 12_[ PRIMARY AR TUBE $ GuiDe 2OULER BALL BEARNG]| 1 estaze ARK Nave OF PARTS Rena NAME OF PARTS [ay TaevanesROTARY CUP BURNER SEALING RING FOR PRIMARY AIR HOUSING WASHER 4._SEALING RING WITH LABYRINTH GROOVES 7__ALLEN HEAD SCREW 2 RETAINING RING: @_LOCK WASHER 3 GUIDE ROLLER (BALL BEARING) ‘3 SPACING SLEEVE LOCK WASHER 30_COMPRESSION SPRING 5 LOCK NUT 6 ECCENTRIC SHAFT 2 PRIMARY AIR HOUSING MPR-1220-hAIR FLOW DIRECTION R40 ROTARY CUP BURNER: SECONDARY AIR DAMPER AND CONTROL LINKAGE DAMPER FRAME DAMPER LEAF ARM LINK ROD WITH SNAP CONNECTION BALL JOINTS ARM LINK ROD CONNECTED TO THE BURNER AIR/OIL RATI CONTROL DEVICE MPR-1220-iROTARY CUP BURNER: 67 8 PRIMARY AIR ns << CONNECTION 4} OIL CONNECTION DIAPHRAGM HOUSING (UNT!-DRIP DEVICE) COVER DIAPHRAGM HOUSING PLUNGER. COILED SPRING. SCREW WASHER PLUG MPR-1220-jCehnhan Kaan \ ROTARY CUP BURNER: F. 0. FLOW REGULATOR 4_VALve HOUSING 2 werening sugye 3__VALVE SPINDLE LUG (fiRC ATI Ol i SCALE PLATE ‘5 POINTER, 10 LNK ROD MPR-1220-k| [| PE. INING SOCKET (REAR] 002 “0” RING & SLEEVE 03 "9" RING 0S SPECIAL SOLENOID WiTH SPINDE 07 TERMINAL Bo} 08 “0° TYPE : MK-15/25/20-MS (COAXIAL TYPE) _ | | QO ROTARY CUP BURNER : MAIN F. 0. SOLENOID VALVE VT bb | 909 BOLT & NUT Ege RING ESLEEUE OV_VALVE-SEAT COMPLETE. 012__JOINING SOCKET (FRONT) F, 0, TENPERATURE..MAX. 1400 F. 0, PRESSURE...n0 = &Okg / m2 SEALING. 0 ~ 40kg / em? VALVE POSITION.......NORMAL CLOSE MPR-1220-taah | | eee 6 1 a NS 40 [ [ A + Steak eL_ 5 ha 5 3 8 | 4 3 1 2 > = PETORO ROTARY CUP BURNER’ ir oil control linkage 1. Olt control valve 8. Follower 2. Control arm 9. Follower shaft 3. Ball joint 10 Quick release connection arm 4. Link rod 1, Modulating control motor 5. Arm 12 Secondary air damper 6 Air? cit ratio control device 1B Low fire start interlock switch 7. Adjustable cam MPR-1220-mLe Primary air nozzle Rotary cup PETORO ROTARY CUP BURNERS. ocation of primary air nozzle in relation to rotar} Burner size| Distance “A” mm R-3 1.5 R-15, 15-2 R-25 2-3 R-40 3-4 MPR-1220-n DATE 080606MAINTENANCE & INTERVAL RE / RR Y BM T NO. ITEM. JOB ITEM INTERVAL REMARKS wR a 8 aM a % 1 [Fo.pRessune — sunt cHEoK ALLTINES —_|sET-PRESS. FOR SHB ; 0.2Mpa PRE Bae oF BIRO ALIS Nor. 03Mpa TH ~ WEEKLY a 2 [ROTARY-CUP IN-SIDECLEANING & CHECK | Lovato] [CLEANING OF INSIDE AND CONFIRMATION OF MOUNTING POSIT. BSI) eR RU ER AFTER WO. COM. |B OHIRRU— 27/20 yi ORE. sain IROTARY-CUP HUS DIS-ASSEMBLING & ‘DEPENDING ON THE DIRTY CONDITION, THE INTERVAL 3 | eoistaBuToR CLEANING) © MONTHLR [To BE CHANGED, Deg dyT NT SRR 1717 BNR LOT. EOMMRRBLT PSY A Taek | See oe | WEEK / | CONFIRMATION OF ELECTRODE MOUNTING POSITION. 4 JISNTION BURNER [CLEANING & CHECK) TWICE OR MORE | VISUAL CHEOK OF ELECTRODE CLACK aka fai RU | LL aN [LD cok oer LDA Dgk OUCH A ROBE 5 [FLAME-EYEGLASS CLEANING & CHECK) WEEKLY _—_| CONFIRMATION OF ELECTRIC RESISTANCE (600~20k) Wh o | He RU 187g ‘BAA OREN (600~20k2) (DDEPENDING ON THE DIRTY CONDITION, THE INTERVAL g [STRAINER SOREEN CLEANING WEEKLY TO BE CHANGED. ait th Be IB PEAABIC OT. TOMAR RAY | — 7 [BURNER BELT VISUAL CHECK WEEKLY _ADJUSTWENT OF TENSION AND CHECK OF CONSUMETION NN | Bam 1S ABS — RAMMERU RA ORE g AIRV/OLLINKAGE VISUAL CHECK WEEKLY CHECK OF EACH BOLT & SCREW. a7 SRS | BRA 18/18 | Babeatty DRAHOBR ‘CHECK OF ABNORMAL SOUND OF BEARING FOR g [BEARING AUDIBLE CHECK MONTHLR IBURNER MAIN SHAFT & EACH MOTOR ary Ree | 1G/17 A A-tE R/T Y ORRROTR Serre aeereeeeeeeaneea ~~ CLEANING OF HEATING SURFACE Freee 10 [MATER ELEMENT CLEANING & CHECK) YEARLY ELECTRIC TVPE CHECK OF TERMINAL WIRING CONNECTION maRaeTL |B RUS FRE 1B 17% MRR ARR BS SMT SORRY OBA EMONM 11 feucoTmc parts |visuAL cHEoK MONTHLR [CHECK OF TERMINAL WIRING CONNECTION anes ae | 18/178 SHAME SRM DBAOAM +4 ra RotS TYPE: 1.5mm~2mm R28 TYPE © 2mm~3mm R40 TYPE Smm~dmmROTARY CUP BURNER : DETAIL OF DISTRIBUTOR (7atNICs-9-840) ROTARY-CUP A’ SSY DISTRIB AIR NOZZLE P_No. 36 PR M, P No. 47, 4. REMOVE THE DISTRIBUTOR FROM BODY WIC a IE THES ORY IL TREY 2, REMIVE THE “C” RING. "CTEM LTRS. 3, DRAW OU THE INNER-TUBE FROM FRONT SIDE AOAC ABERBL TEE. to" RING 4. CONFIRM THE CONDITION OF “0” RING AFTER CLEANING. THEN RE-ASSEMBLE PARTS. WRK. “O" NTOREERBOL, POMRCMALTTRSO. 0" RING P Wo, 55 "0" RING P No, 56 Ss MPR-1220-p[eee | sooerarie TT = |g |~ sence asec cans | SSeS bee aa | a Dae ze = 2 me ec =| ares x wet [epee [wren $—| Sarascane—[t = aera [+ en Te | ama Naw OF PaaS jor] "ES Te] ye aoatae uN NMPR1361 DATE ea TYPE Ro. 1572540 SUNFLAME CO,, LTD, cee yap Bote | 20.2007 | EXPL waked o> Sb A Tes praululeed to Uivari of Gstribate Te Goumat saywieve oiaer thee tie oelaliaitg parva TRAUERRANCARTOR: ROT EETET.NAME OF PARTS REMARKS. YT R234 | ROTARY CUP 1 18 ROTARY CUP HUB 1 “19 [romevcrwecve| 1 21 [ALLEN caP SCREW 6 22 | LOCK WASHER 6 23 O-RING 1 29 HUB SLEEVE 1 ROTARY-CUP. EXPLODED VIEW MPR-1361-a ee TL Ty | eter SUNFLAME CO,, LTD, at UY DLAR104 DIRECT, OF ROT, oes Gri :auseGx1 74 0.1702 MPa Poi PAUBBGXI74 O-1.0 MPa TYPE TROCHOTDAL_GEAR es Noo eK Ps & TPH BOT A‘, 7 MODEL NO, eR I~ 0-39 CH) ree FTP - Ns20H2SF FLANGE SIZE CAPECITY | ka/n|—766—| 2 300 222 DEL, PRESSURE aTRTNPE nak a JIS 10K 404 - JIS 10K 254 506, PRESSURE paOteSE NPE ww 10K 25: RP HSC 888 ben (an) 1, 800 TE FORT BTR ORT AS =) PRIME MOVER Gageto-e-9 (8) F" He | eee tesa be | 2, 2 kW x AP ees | 27 ke WEIGHT + 55 ko aoe OWDERER & 5.0, a ® a = 7 RXEROOE DRAIN BY, oe FUEL OIL PUMP UNIT ae a RRM RD a’ ‘g|soauaroep eS Mp - 25 19 DRAWING HISTORY pautint coor HB SUNFLAME CO,, LTD, gee | ven uxet bo» 72 LAQE 2QGO eR DOG S SQ Wit a a) ae VY fd Wy 7 Yi? FI / taney 25 416 | 4-126 149, eri 134 21 178 yon ten Tsar Bi [soi Tysae a THPE : TOP-NGZOH-08 ar 7 [auc seuaine [i [paaautaceg pr [rer 7 ser 2 a [ev coven Tp Feaso ia ar ae Thess 25 [ct Senate Thema —| FUEL OIL PUMP [aivar 7 | tanie £67 1 [susaan TT | PACHTNS 1 [PAPER 27 [oui SEAL 2 [aes FOR USD x - 3 [ree sore 11 ra [racer [aes Bio Bint [eae Sone 5 [ouree eoror r 15 | 8007S. reo ‘25 [Seal woUBiWe “8 |! | FCD5O Rf < [pa Serr fsa ra caver banks —— To a0 30 | seat woosine =a | [roan TaN. yp poeaperte 20-uiR 09 5 [pean woos ra [a a 2 [es 2 [sracbe fees a ¢ at 2 [asian trae | [rabeao ——[ 2 frou © |reoans——— [27 [sours [ss ‘Tow s007 Z aa ass 2 [eetieF Wave [7 SUNELAME CO,, LTD, TT CA a HAHAH bYDLA vOre1) ATOM] ZBR DIF RIA ayorse g 2) eae ; 3) LOCK-NUT “ 3) Beet 5) HEX, WRENCH 5) HALYF (4mm) AV STRAINER 4) AbU-t 1 Over-haul of Atomizer When you clean the atomizer, please overhaul as shown in the left-hand sketch for e: clean. Please be aware of the direction of Disc.2) when re-assembled. Strainer 4} is not installed on the atomizer in case of C-Oil since impurities like t. will be adhered on the filter and this will use bad o11 flow. FRVAFORR FeV PRAOMIE, t. MM CORICIL, 2) MOBOMSICTERK SL, WHC MOBS, A bL—FICS— RO RAL MAHAL MORNEMSLETOC, AAL—FIMIMAL THY ET, DE FIST HEE Y ARCS H16-5KAJIWARA HEATER PIN TUBE & COIL TUBE Type Oil Heater Handling Instruction 1_ Installation This heater should be installed horizontally so that drain pipe faces downwards and the drain outlet is positioned at the lowest level, as illustrated below. It is important to keep the specified maintenance space for inspection and cleaning. The maintenance space required for these is shown on the dimension drawing, ‘The drain pipe must be provided with a steam trap. The oil piping should be cleaned by air flushing before oil running. 2 Operation Before starting-up the heater, the oil circulation must absolutely be started before the steam is let into the heater. At shutting off, the steam supply must be stopped before the oil circulation is stopped. This is important to prevent the entire system from damage caused by caking and plugged of the heater element ‘Therefore, please check if steam valve is fully closed and there is no leakage from steam shut off valve. 3 Maintenance ‘The capacity of the heater is designed based on the saturated steam at the required steam pressure. In case that 2 reduction in heater performance is confirmed and found that steam system is properly work, it might be caused by dirty or plugged heater clement. Therefore the heater clement must be taken out for inspection and cleaning. To clean the heating surface, wash with kerosene and blow with steam or compressed air. In case that itis difficult to clean contamination with such methods, use carbon remover chemicals such as trichoroethlene, (On building the heater, use new gasket, and tighten every flanges carefully (tighten symmetrically). BS aaR410 004, e418 005, Raid 008, R416 Rai 007, aid 008, e418) 909, Raid 010, a8 oui 418 giz (Rand) Uy) Ray 008, wD) \ \ OOS yew R4IG | PACKING FLEXIB, TUBE TO BURNE: a oid yey 7 Reto KFAOILED IN. Fa—3 | | AOA 2415) TERMINAL COVER 1 Tne ooo | ment RAI TERMINAL SLOGK ilar RITE | ONTL-DETP_ DEVICE COMEETION | Tg, 008 Rte O18 £RHERERRO Bai T PACKING i BELT RIEL OF, TW-LET 1 Tem 007 yey a7 WAY OD R416 | SEALING FLANGE ; RATE | NIFPLE ise (ua Hirai [acs rte IFDd. O16 =e : RULE T FITTING SoBe BALE FITTING SOREW os | mb HLU: 4 | Moxd) Gis | meee 4 [Mani RAIS], RING RAIS) TEFLON RINE 3 ooe | om yd U [peoxa¢ [ia | popes arin R418 FITTING FLANGE RATE] Or AINE 003 | ROH 2529 | ois | Or uy et eeaie RAE | FITTING ScREW ore oe 4 [M4x10 Rab | HEATER-CABLE 7 lah ae [Rare | coven 7 | ssvo0 001 MB7- 5 (5,95 O/m) | O11 Di e WARK [NAME OF PARTS: io TY] REMARKS MARK | NAME OF PART [O° TY] REMARK: BS | wee wR al @ 4 | ee) es eg cROERER & 8.¥0, GRECKED 8Y ERERUBE af EARN BY DETAIL OF PIPING HEATER ® oar sore ia Ree-9Rwe ; rate oe | HAE RG O5-APR,~'02 5B | gq’ | a | O6-JAN, -' 06 @# GR- 1362 manne nism | Anne come BE SUNFLAME GO,, LTD, WONEELL + 5 * B RASH YH YUIDIDLAwn 6 i G é ws € “5 - Q AER seri OFF p 5 JD teres a a mt [RTBTS eru-vst|i7s| 60| 25 ame [fin ae gi erate eee eat eat ett or a7 fee iirei izes | Sree T Tp» Pas wore (| TYPE:GFH-V5L 7 ee ‘ oe [See TUE, [| FUEL O1L PUMP : : oe eae bar Ph pcm RAWLS ; : pe eer a he 2 : ! peso | MA- 1076] Bi" | eat a ; Pe SUNFLAME GO., LTD, E “omr rl &itet 9 > 2LA9 ae 08:28 BITON 7 7 sh 5 a 7 er ra ae 7 sea 7 [ae | Crate aba Ba 7 a pele Te rls ee [4 ae scanszaivon | 7 | 33 | POO rng om 620 4 ee 1 | 32 ieeeae 6025 L4 7 rar pack 7129 tees 7 10 | 1 (28 ae Tw 1 Fl - 7 far | eae aire 7 7 ra TV pg | Pe abe a ; rad 7 Las |e ig ar 7 5 ar 7) 2g Pe peas 7 7 Sir 1 Tag | Pea orn 7 Pheer 11 2p] Camahet obra ag 7 oo ez 2rAamoie ? Ta TP 1a BERS 7 1 ead 1 | 20 ned 1 Wet TT aR aT at ih. fff 8 ae orogReR & 8.40, GEECKED bY j EXGROKE a SPOT oa | DOs PUMP CTYPE GFA) Erection diagram scrie DO. YI (GFH®) @o8 Rw a’ ''y| ame | ge Ex-10000 carne wiser | Arie coon 2 RE SUNFLAME CO,, LTD. TNE . wase | Sen eked pou 27 vA2608 pC VN =| X = DETAIL OF RECTIFIER P.O, TEMPERATURE ... MAX, 140U F, 0, PRESSURE ,..,., 0 - 40ka/om2 SEALING vevseeeeeee PTFE VALVE POSITION .,,, NORMAL GLOSE No, [ai OF Fars wat aca EL DOT [voinmne sooreT Wea) ADIs 77 F O02 [roruine 8 seve" 0" Vy 9/zT-F co (1) 7 1 03 [Forum Toryy7 td olololo One jessie Sree ERI i EEE [0a [SPECIAL SNOT ARYL 4K sam | I 06 | cone witk sriNDLE AE Rwy 1 Di D|D| a a O07 TeewiNa wor wre 1 08 [oun * OF 99ST 1 ig | +. : i 1 SOLENOID YALYE (20) —— 000 Wor & wor uke Fah 110 Powe 6 sie" ON Vy F/ad—F OL [WALES CORLETE TOUT Ma Ia JOINING SOCLET (FRONT) BOM 17 F ‘ORDERER 2 8, NO, ANERU BE TYPE + MK-15/20/25-MS GOAXIAL OIL SOLENOID VALVE (N, C) are in wees CARE) ‘Ths osmar03] gt Mv - 2 4 6 2 wearin wievorr—|_patntine couooe SUNFLAME GO,, LTD, Seen We atest bv DLAsockeT Tre F €-678-20 28 6 455, CONSTRUCTION. RESINOUS COATING en one 24 4 + oy 5 li | | 2-006 é be ese a & LEAD WIRE T= Fa CERAM! CBASE en, Ayu rva 300.6000 ougnen, sror s20Ka aie ORDEREE & 5.0, a 8 : ] cxeocen oy a en a a TRAM BY FLAME EYE & SOCKET x a perc NO DU-hiP4 Ro Yooh R DATE Pag | Oe 1 a ‘4 | O3-AUG. ~* 84 # A - 1045 wearing wirony [xine covoun HE SUNFLAME GO,, LTD, MiNSELL . ee ate Y vy 7 LA49.4 38 SOURCE ge coo a CRDERER & 8, 0, ERBRV TYPE : FE-O1R FLAME-EYE RELAY Deawing ¥is7ORY ama BY gel 0 JU-AP4 +d LH a’ Sg | 2a-apR oo | gn A- 1044 palnting cove 383k SUNFLAME CO,, LTD, @ i k # WONBELL ze RASH Hy D7 vAR407 2904 Wawe OF Pant [a stv] REWARES New | 58 a lea | as 1 aoa? 2 | cas TNTON, 2 piety y 2 | 26a UNION RUF z FLAME-EYE 3 Dee oe ys 1 | 26a To=as Fd FAGEING 4 ree 2 eee z Lass 5 woes t 4 WIPPL a 6 ee 1 | 28a EOCET ! 2 vor yt t WETAL SOGPET 8 Penaseys | t | 4p 260 OOOOQOODO WW We / / as BURNER RUNNING —— 300~60029 BmhRE MONSELL zyey A+ #e BURNER STOP Wat a — >20K2Q peda ORDERER & 5, NO, ‘CHECKED BY EXER GE a = DRAW BY FLAME EYE pee SCALE V1.5 Puo-A+74 jy [ovo -o [BEG - 1 4 6 8 suasine eistorr | raintine cour SUNFLAME CO,, LTD. eked ¢ YI7AVABACK CONNECTING TYPE (PLI1) BH (PL) BAM AYy PANEL CUTTING (sorrow view) TRACK MOUNTED TYPE (PF113A) ‘a % (PFLLSA) warns (ror vrew) SeEROME eee A 06 - AUG.-"84 DRAWING ISTRY PARTING COLOUR 28 BE SUNFLAME CO.,LTD. eoee [et ated + vy DUAR06 & R509 a4 TYRE a low AC CODE No. ClaEDTEBTDDY #3 0196732(220V) -D PRRTRTION sais iP 67 @) Wrion NORMAL CLOSE ae a (9) Wiss _f OS ko VALVE BODY # TYPE ‘CONNECTION |Kv- VALUE] PERM Bee MEDIUM] MEDIA TEMP, |TEST PRESS. MASS Bx HBO Kv ie iia Re hE RBH |e & F42108|ps2us605| ¢ ave" |0, 5529/4 =i 0,0, |-10~ 100 | 5.0MPa |0, 2kg ae 0. 5ko “0, RING ee Tew TRNATURE, FLANGE_ SCREW VALE SEAT 4 575 n= +757 Sia) 4 [808304 eas ce EARTH TRMATURE 3 te ) 8 | ARTE yy - | | sussod TP. CONNECTOR OLOSTNG SPRING 2 VAMP a + : (Anau Peer TERMINAL BOK VALYE BODY e 1 MAL 1 6 | Aye 1 | seas No, | NAME OF PaRTS PTY] REMARKS |[ qq, | RANE OF Ty] REUARKS [8 eH #8 [8 as Tot aie wit «5, aah is Dawe at oman 0,0, SOLENOID VALVE 2 8 GP pbsnantnapntnanagonsntenpassnunssnsssisens=t0naahat senLe is DO. 8 HH R_& : DanORS Dyes Tee ogeea, 03 | mame foapuspn7 | a | tf | O4-FEB, ~* 03 MA 056 DRAWING aisTORY Painting coLour HB ETT co,, LTD,R701 (R302) fee | dt | IS 10K 25A 330 a ° 2 g 5 @ +e EQUALIZING ORIFICE ‘CABLE GLAND. SSEBTUI42 0 | eR ISUE 1 | 1% ARMATURE, SPRING 1 9 ‘SERVO PISTON 1 Zoy3r~ itt SoS ERDY PILOT ORIFICE 1 8 CLOSING SPRING 1 | ityoyh tu742 Baia VALVE SHEET 1 7 WAIN ORTFICE 1 AWD + yb EAIIIR 7 | OO 1 | DUAPHRAGH 1 an 94775 b TAME OF PART, ET REMARKS I ,,, | MAME OF PARTS IE RENARRS 8% epee | eK wees Tole OROEREK @ 5.0, a BRE RU RE a of TYPE + EVO25E 2560 aah BY VALY. o's = STM, SOLENOID VALVE soait RSQEH (aRST R gz NO 3) & amen [SS Mv 160 4 6A ravine aistonr | raumine com 2 HE SUNFLAME CO,, LTD. HUNBELL . Bare | ven exe YoY DLANAME OF PARTS TY [REMARKS MARK [NAME OF PARTS TY [REMARKS 2s] a 8 os ® eoet a os |e s{ ae ws sala 3 rroe (0.0. 1N-CET 7 Rye [ELECTRODE Doe |" A # a ho eS te ous | tug o~ 2 \aii7eo R108 [COMBUSTION ATR (N-CET RiGe|PCUG_CAP OOA | # ® F&A Pees ooo | “35 9+3 hy 7 | 2 Rigg {ATOMIZER 1 [So 18:38-80;]R108 |ECECTRODE HOLDER Te (ria ale 2S Robi 40:46-60'|o10 | See 8 a 8 Ri 98 (NOZZLE HOLOER ress Rios [INNES eCECTRODE-WiRE | > woe |e ew nS or | RBI NON KD) | mop {Oil Pipe Rigg |JOINT ELECTRODE Oe [OTL PEE 1 [ea stpcazo [ROB [POINT ELECT [2 [enzao Rigg [ELECTRODE HOLDER ‘i POSITION SETT. RING 7 ood eee ae feRea eT Rigg {TG BNR, GUIDE PIPE Rios |SErTtING scREW 008 | ain ead ! Erie i {2 [Maxie 14 96 |ABSEMBLY- FOLGER Rog (SETTING SCREW Doe Te SoG wee | id eee ] 2 mars 108 12 108 908, 108 GOA 08) 005 > ws) 08) 08 008 108 903 108) 002 aa Ave dd Roe | ub l 20. Tee [A 2 | 55 B _ R9715| 1025 o70 | | a [reavao| izes | 1170 7m THE ORE, TNT a Rw * Peeevais a 4 GR-1313 CHES BF OE THE: PTR-25B ae | es fe | IGNITION BURNER ASS' Y SUNFLAME CO,, LTD, FATE BOLT ae ARN -F@OB RRSH UUILDA eoreAC/DC Converter in Control Panel The average life of AC/D converter is approx. 7 years due to the less function of Acts in nal parts 1-2, Fromabove it is necessary to replace it approx. every 7 years and the label showing below is attached to inside of burner control panel for the recording of the replacement Sample of the Label for the recording of replacement * Record of Replacement of AC/DC Converter Regular replacement to be required every 7 years to avoid the trouble | Date of replacement First time | Second time Third time s|s/s|= Forth time | we ficp ic |ic | se Fifth time s As for the spare of AC/DC Converter on board,we recommend to stock wher it becomes necessary since there will be less function as the same reason as above Euergency counter measure in case of non-controllable ue _to the less function of AC/DC Converter 1-1, Stops of emergency counter measure. 1) To prepare DC24V from the monitor room of the veesel.All electric sources to be off 2) To remove the wires connections at DC of AC/DC Conver a} Remove wire connections of “P” and °N” which are printed at mark tubes at the ends of DC output b) Remove “P" wire first and then remove “N” wire (in case two wires are connected at one terminal, remove both wires) 3) Connect both wires of “P” and “NY te oczav a) "N" to connect “Minus” of Dczev b) “Pp” to connect “Plus” of pczav (in case two wires are comnected at one terminal, connect both wires) After abeve connections please wrap both wizes by vinyl tape for the protection. 4) All electric sources to be “on” and to operate the burner And please confirm the burner operation without any abnormal conditions Above 1.1. is emergency counter measure. We recommend to replace AC/DC Converter., a8 earlier as possible, which is not in order Notes) Please note that photograph attached ie the typical one and the =uabers parte of arrangament will be different from the photoDIGITAL INDICATING CONTROLLER SDC312G (STEAM PRESSURE CONTROL) USER'S MANUAL a) NAME & FUNCTION OF COMPONENT PARTS ‘80034 (96 mm x.96 mm size) "(ae Ge | — © No.1 indicator | | @ No. 2 indicator © Mode LD —9 © Groonbett +— @DISP key @SPREVUF Key -ED AO -orre MODE key we) “Ow || oon [J] ~ © Loader connector @aNTiey @® No, 1 INDICATOR @® No, 2 INDICATOR @ /0UT SP LIT our LIT SP - OUT LIT SP FLASH ‘QUT FLASH EVI~EV3 or REM at @® GREEN BELT © DIsP KEY ® SP/EV KEY = INDICATES A PV ( STEAM PRESSURE) AND ALSO INDICATE THE CONTENTS ‘OF PARAMETERS. = INDICATES A SP (SET POINT) QUT(MODULE CONTROL MOTOR OUTPUT %) ‘AND ALSO INDICATES THE CONTENTS OF PARANETERS. INDICATES WHAT IS EXPRESSED IN THE Ho, 2 INDICATOR. INDICATES THE SP. INDICATES THE NODULE CONTROL MOTOR OUTPUT (9%) INDICATES THE NODULE CONTROL MOTOR OPENING DEGREE (%) RAMP IN OPERATION. INDICATES THAT THE CURRENT 1S MANUAL MODE. = LIGHTS WHEN AN EVENT OUTPUT IS ON. = LIGHTS WHEN THE RELAY QUTPUT IS ON, AND GOES OUT WHEN THE RELAY 1S OFF. = LIGHTS WHEN REMOTE SETTING INPUT (RSP) IS SELECTED. {FLASHES DURING AUTO TURNING OPERATION. + LIGHTS WHEN THE VALUE I$ WITHIN THE RANGE PRESET IN SETUP ITEM C43. FLASHES 1M READY MODE. = SET THE DISPLAY TO BASIC INDICATION STATUS. INDICATES A PV ON THE No. 1 !NDICATOR AND AN SP ON THE No. 2 INDICATOR. SELECT THE STATE BY WHICH SP, EVENT AND PARAMETER SETTINGS REG! STERED 1TO THIS KEY CAN BE SUBSTITUTED. @ WODE KEY ‘Select AUTO-TUNING START/STOP, AUTO/MANUAL, RUN/READY, AND LSP/RSP NODE CHANGE ITEMS. @ ENT KEY = DEFINED THE CHANGED NUMERIC. SET THE ITEMS SUCH AS DISPLAYED PARAMETERS TO A CHANGE STATE. @ W a key + INCREMENTS NUNERICS. SUCCESSIVELY SWITCHES ITEMS SUCH AS DISPLAYED PARAMETERS. @ OWN W KEY + DECREMENTS NUNERICS. SUCCESSIVELY SWITCHES ITEMS SUCH AS DISPLAYED PARAMETERS. @ LOADER CONNECTOR = NO USE b) BASIC OPERATION FOR SET UP. 1. HOW TO CHANGE THE AUTO/MANUAL MODE. IN CASE OF CONTROL THE F. 0. /AIR Contral (MODULE CONTROL MOTOR) MANUALLY, PROCEDURE 1S AS BELOW. [OPERATION PROCEDURE PRESS THI KI & ‘THE MODE USE aoe @ iE MODE KEY @ CHANGE TOWICE TO INDICATE THE ayy KEY Peer ree ear eee ne =P OUT 1S INDICATED FLASH BASIC INDICATION AuTO. 1S INDICATED © CHANGE THE OUT VALUE @ PRESS THE ENT KEY TO (woouTROL MOTOR OUTPUT) SET. SET THE OUT VALUE USE © “4 MODE CHANGE TO MANUAL. A/Y KEY. OUT LED STARTS FLASH. IN CASE OF PUT THE POWER SOURCE ANAIN, SET UP ITEM C14 WILL BE INDICATED. 2, HOW TO CHANGE THE RUN/READY THIS PARAMETER ALLOWS YOU TO SELECT THE READY MODE IN WHICH PID OPERATION 1S ‘STOPPED AND THE RUN MODE IN WHICH PID OPERATION EXECUTING. [DRERATION PROCEDURE ® DISPLAY RUN USING @ PRESS THE DISP @ PRESS THE MODE KEY yy ey aaa KEY TO BASIC => TOWICE TO INDICATE THE fas je hoi canes LAS INDICATION. MODE. @ TO DEFINE THE CHANGED WODE, PRESS THE ENT KEY. | [ERECK ITEMS ‘THE INDICATION RETURNS TO THE GREEN BELT FLASHES IN THE READY MODE. BASIC INDICATION STATUS. WHEN RUN//READY SWITCHING IS SET TO THE EXTERNAL SWITCH INPUT FUNCTION, RDY OR RUN WILL NOT BE DIS PLAYED EVEN IF THE NODE KEY 1S PRESSED. 23. SET UP OF NODULE CONTROL WOTOR AUTO ADJUSTMENT. IN CASE OF Steam Press. Controller, AUTO ADJUSTMENT THE GAP OF MOTOR FEEDBACK RESISTANCE FOR CONSIST FULL OPEN & FULL CLOSE OF F. 0. /AIR Flow cont. (0: ADJUSTMENT NON ACTIVATE 1: ADJUSTMENT ACTIVATE DPERATION PROCEDURE @ SET “1” OF SET UP @ START THE BURNER. @ START THE AUTO ADJUSTMENT ITEWC36 AT BURNER STOP. CONFIRM THE DISPLAY _ BY WODUTOROL WOTOR FULLY (rdy INDICATED 1) CHANGE TO “run” AND CLOSE (CA.CL) ~FULLY OPEN GREEN BELT FLASH STOP. (CA. oP) PRESS “ENT” KEY 4, SETTING OF DEAD ZONE. IN ORDER TO STOP THE MODUTROL MOTOR HUNTING, INCREASE THE VALUE OF Set Up ITEM C34(0. 5 ~5. 0%) (SEE THE ALTERATION PROCEDURE Set Up) EXAWPLE) ALTER C34=3 => 5 ¢) TROUBLE SHOOTING. @ IF ASET VALUE CAN BE INDICATED BUT CANNOT BE CHANGED, THE INSTRUMENT TO SET LOCK STATUS. ‘SET THE SET UP ITEM CO1 “KEY LOCK” TO 0. EXAMPLE) I)PRESS ENT AND W KEY SIMULTANEOUSLY 3 SECONDS. => 2) >CO1=1 FLASH (KEY LOCK) INDICATED => 3) FIRSTLY, PRESS ENT KEY , THEN CHANGE THE FLICKERING VALUE USINGA/W KEY TO 0 => 4) ENT KEY TO DIFINE => 5)DISP KEY TO BASIC INDICATION @ THE OUTPUT VALUE IS NOT INDICATED, THE CONTROLLER IS IN EITHER READY OR MANUAL MODE. PID OPERATION |S EXECUTED IN THE RUN MODE, AND THE CALCULATION RESULTS ARE TAKEN AS THE WV VALUE IN THE AUTO MODE. @ THE OUTPUT VALUE 1S NOT INDICATED IN MANUAL MODE. CONTROL SYSTEM OF MODULAR CONTROL MOTOR IS C35 = 2 (NO FEEDBACK) IN THE NO FEED BACK MANUAL MOD, THE OPEN RELAY OR CLOSED RELAY CAN ONLY BE SET TO ON. @® MODUTROL MOTOR HUNTING. ADJUST THE FEEDBACK RESISTANCE OR SETTING OF DEAD ZONE (SEE 3. 4)d) ALARM INDICATION THIS INSTRUMENTS ALWAYS EXECUTES PV INPUT CHECK, OR SELF DIAGNOSIS. IF THE PROBLEM DETECTED, THE INSTRUMENTS INDICATE AN ALARM CODE ON THE No, 1 INDICATOR ALARM CODE TABLES INDICATION PROBLEM DESCRIPTION MEASURES y PY INPUT EXCEEDS +10% OF THE RANGE. | CHECK THE SENSER, WIRING, PV RANGE AND | ALOT |” coven-tance) TRANSMITTER. | ano | PV INPUT LESS THAN ~109 OF THE RANGE. | CHECK THE SENSER, WIRING, PY RANGE AND | ALO? | cuyoen-ravse> TRANSMITTER. | ALgg | LINE IWPUT ERROR DURING PTD INPUT. | CHECK THE C LINE WIRING. 3 ca inPur enon DURING 1/6 INPUT. | ASK FOR REPAIR. RSP OVER-RANGE. “| CHECK THE RSP LINE WIRING | ad CHECK THE RSP_ INPUT. | RSP UNDER-RANGE. CHECK THE RSP LINE WIRING. aad CHECK THE RSP INPUT. T LINE BRAKAGE, FB LINE OUTPUT ERROR. | CHECK THE FB LINE WIRING. ALOT | occurs owt at 635=0. CHECK THE FB INPUT. Log. |MTOR ADJUSTIENT ERROR, WAV ADJUSTNENT ERROR CHECK FB LINE, AND RE-ADJUST. ALry | #2/06 comveRTER eon, ASK FOR REPAIR. a Lg | PARAMETER ERROR. RESET PARANETER (TEMS. Lge | ADJUSTMENT OATA Eno ASK FOR REPAIR. |Ship yard © ‘SNO. Steam Press. Controller TYPE $06312GA000500 1) Basically. please do not alter the Set up items 2) Alteration for the adjustment is allowed only * marked data in PARA,PID,SP section, 8) In case of alteration of the setting, each items is shown on fist indication, setting value is shown on second indication. If the alarm-code has been shown on indication, please refer and confirm the contents in trouble shooting. 5)_Please refer to the operation manual for how to alter the setting and how to use. ete Set Up Setting Set up [Set vaive | Setting | Unit Description cor 1 Key lock iangeable O=unchangeable 03 0 ‘Control action co4 40 ‘Type of input range cos 2 Input decimal point position cos 0.00 Mpa | Input lower limit (SIM. Prow) cor 1.00 Mpa | Input upper limit (STM. Press) CoB o LSP sotting system cog 0.00 Mpa _| SP lowor limit (STM. Press) cio 1.00 Moa | SP upper limit (STM. Press) cit 1 ‘PV input abnormal setting O=donithave Ihave Cl? i RDY or PV abnormal output C13 0 Manual mode output ‘0=don't have Ihave C4 a h Preset mamual value cis 0 Output in RDY Cie 0 No use ci7 0 No use cig 0 ‘No use 20 0 No.use cat 4 Vi output C22 0 EV] output standby action cz a V2 output B=BV direct C24 a EV2 output stand-by action C25 a EV output in RDY C26 a SP for External switch selective: C27 1 External switch input 1 1=Run/ Ready 28 o External switch input 2 cz — Bxtornal switch input 3 30 External switeb input 4 #04 Out of sensitive range 635 1 Modutrole motor contrel system *C38 1 “Modutrole motor auto-adjustment start O:non-adiustable condition _1: adjustable condition C37 528 ‘Modutrole motor fullopen adjustment value 038 4459 Modutrole moter fullclose adjustment value 639 3 Modutrole motor full-open and close time cao 0.03 ‘SP lamp rise curve cH 0.00 'SP descent curve ca 0 643, 0.05 Mpa __| Green belt range Tn_case if SP range, ON cua 5 Kinds of Auxiliary output chs 0 % | Auxiliary output 4 ma C46 100 & Auxiliary output 20 mA ca 0 No use cst 0 No uaaIn cave alteration of the setting for Set Up parameter. 1. Set Up parameter is changeable only RDY pode. When the burner stop it change to RDY mode autonatically. 2. Set Up al terat ion press ENT key andWkey at the same time more than 3 seconds => @indicate *601 > @Firstly, press ENT Koy ,then change the flickering value using A/Wkey to 0 => @Decision by ENT key => @)Press DISP key to return original, If you alter the other € (setup) setting, press A/Wkey to select. 8. In case of Modutrole motor hunting. Raise the 636 non-sensible range value 4, Modutrole motor auto-adjustment. Ifyou change the motor, or resistance of motor feed back is changable, uso the auto-adjustment of C36 Reads = Qset ww 1 => OSlart the burner, and indicate RUW, press the ENT key > @auto-adjustment will start, motor closeropen—elose, and finish If the error happened, please try again. Please set_up +##* marked places according to the specification { Set point [xSP Mpa | Setting value EV [ee Mpa | Burner startistop EV. | eee Moa | Spare 1. Alteration of 8P control position press SP/EV key one time => @indicate $P => @alter the flicking value using&/Wkey > @decide by ENT key > @Return original by press DISP key. 2. Ifyou change EV Burner start position ‘Opress SPIEV key twice @indiata EVI => Galter the ficking value using/Wkey => @decide by ENT key > Greturn original by press DISP key. PID setting (+P 15.0 1 _| Proportion range [er 20 Sec | Integral time a 0 Sec | Differential time ja t % | Control eutput lower limit, ex)10 set up! control start at | 7 10% after ignition *OH 100 % Control output upper limit, ex) upper limit at 90% (RE = | Manual reset TF yow alter the PIDD setting. (Dpress the ENT key and Akey at the same time more than 3 second > @PWO indicate => @ENT key > GP indicate = Gpross ENT key. Ifyou alter the flickering value, use the'Wkey => @ENT key to dacide return ‘original by press DISP key. Setup t#¢s marked places according to boiler specification, [ PARA setting ‘eHys!_ | ee Moa | Event 1 Hystorosis Setting ‘Barer Stop) al u Sec__| Bvent 1 On delay time setting [aeHys? +e Mpa _| Event 2 Hysteresis Setting az) 0 Sec__| Bvent 2 On delay time setting Fit | 0.0 Sec__| PV filter PoLA_ | 0.00 Moa__| PV Bios out | 100.0 | Gontrot output change limit ‘you alter Hyst Burner Stop position. (press the ENT key andAkey at the same time more than 3 second > @PIMO indicate-> @pross Whey => GPA indicato > OENT key > @+ lyst indicate > Dprese ENT key. alter the flicking value usingda/Wkey > GENT key to decide > @retun original by press DISP key. If you alter the other settings, use the A/Wkey to decide, Burner Start /Stop setting example. ‘When the value is Start 0.80Mpa Stop ‘SUNFLAME pa sot the value EVI=!T-301E ve Ye GL hel OPERATING MANUAL CM-101T Series CORBRARE ES BRAOLRE, ELMS OTCA to. eb, RRM SARTCREL TAS, Please read this operating manual carefully to ensure proper usage,and keep it handy for easy reference, CORROMEMRFSE [AREAITHESALMOMEOAMRST ST etsmens| AST. This symbo! indicates that serious injury or only materiel damage may resuit if the ‘Warning’ instruction is ignored. COmmOMELTONEL (RE! WETS, This symbol incicates ‘Prohibition’, that something should not be done. DEROBLLAL TORE (RA) HECHT. iris syreotinciates 2 Mandetory instruction, that something must be done NISSYO1 BRORR cat CTT ybady URED REM BRAS A tye TREE 1, Gyo 8 Model identification owtorT Win poteniometer (196) ~ With goteniomer (220) Tarc-—Model equiopes wit igh (Hi) andiow (1) AP ate air int ches fone ex © fel nape th an seg mt (Ga... Model equigaas wih random seting alarm nit LST swt fe) Power ROVGDV ar B00 San ] “Timing 30° —Oses. 13/36 _{S0/60Hz)_(*SRtFeT) | Terque 25 1 Rating a Continuous 1 Power Conaumpion CW) — Atorox. 26 Frtecive Srueue i | inelaton SH Cane | Potensonaier (Ol 735.200.500,14or o (—WE) | Gontsci Capacity GRAM Aesstance ead _ACISOU 108 OCHVEA | “Ambient enperative CC =10~ 50 | Mass (kg) 3 _] 31 CERO MEDD M RCE CORT ARUTCEED 32 TEKOMMR AH TOS HABL CRED, eee ORRO REE REL CORES a08t. 42 BLOBMRR CBRL EH $3 ENO SOM ORBLE TE 66 KORA SIR ORAL OTE, 45 EMORAEROBSR, TAG a -EU TC REO, eee caeu, eo MEM EAR A: 46-2 BEML HE o bo ORB CREE 463 OOM RB ERO ST ACE HITE wacaets, ET MEM 7D PEED AE REO TES SRS FUD EMM ERERAL TEE: ass, Unpacking $1 Check that the praduct delivered matches the spec: ifications of your order by reaging the nameplate on the product 3-2 Check thatthe product comes with al the accessories oxcered installation Location and Setting 4:1. Use the product within the ambient temperature range specitiad in the operating manual. if used outside the range, the motor may burn or the product may not deliver its intended performance, 42. Avoid operating the product in an excessively vibrating plac. 43 Avoid operating the product in a custy place 44 Avoid operating the product in placas wher ‘exposed to rain and water drops. 45 Place a cover aver ito prevent direct exposure to the son, 48. Set tie control mator as folows. 446-1 Set the control motor so that its main shaft center is in parallel with the matching main shaft 4-6-2 Set the contral motor so that the lever on the contra! ‘motor isin the same olane with the matching lever. 46-3 Set the contral motor so that the lever aperating ‘ange is divided equally based on the vertical line of the tangent 47 It the matching unit has a stopper like a back sheet, a butter like the one shown in the figure at below ‘should be used, it will be5. LIST Osten 16Fa REMOUN-BEOU-REERERAL MSG TROSMERRLTSHED Sif Tins o mt ae 2 vx-BS eR, ALERTS. LRieomTEL aR bRBIRSAE SHENTON THE MR, mee 28x (LHe) OME HEMEL TCE. Ls Pest 0: OMS R PO8 MS CORR I0— 50am AH: s-iyeoSseuriamees ho“ wes BO DwRE STR 4. (ceeaseeacnmOm S21 BEML) (—SOMNETER TS, (kOD ma) 2aysens opwaces. S03 MBB EL MBSR CHESS. ( POASMETORR 30~50ea) EI RAERRMEMETL CTS, Cel) BSG TVA LEW SMU N-EBATE, FY-ELTEK, aut 5-3 met Pe MMC MEM BUT 3-6 ‘SS MERESH GALT AL AEBCEE, CIFOR LE= SDM ED neers. Iesuie v0 5. Lever installation (© [Do natharnmer here aaaeeeree j the shat? and lever when setting the lever on the shat. i hit, proper oneration may be imoeded, Set Matching unit in case the lever and le Nissyo are not used, itis following in advance 5-1-1. Prepare 2 lever which mounting hole positions are identical to the fever supplied by Nissyo, joint fitings supplied by sessaty 10 prepare tne 5-1-2 Lever joint fitings 4) They must be able to move in synchronization with the movements of the levers, and must be prote- led from seizure and rusting, b) They must be of construction in which it is not ‘caused to slip when thrust (700N) is applied to the connecting rod. 5-2 Connecting rod Prepare a connecting rod of 98X(L+2e) Whe: LL: Distance between main shatts 2 : Distance from the center of the lever joint fiting 1 the end of the connecting rod (30 to 50mm} $3. Mounting In the case of a square main shatt or a main shaft with keyway,see the separately available operating manual. ‘The control motors set at the clockwise rotation fit (or at ne speciied position). 5-3-4 Secure the matching lever at positon 0% (counterclockwise rotation limi) 5-3-2 Apply power across MH anc MC terminals until the main shaft comes to the 0% position. 3. Secure the connecting rod 10 the fever joint fittings (cistance fram the center of the lever joint fiting {o the end of the connecting rod : 30 of 50mm) Note : The mounting distance should be equal to the distance between main shatis {L—=L") 5-3-4 Place the lever over the coniral motor main st At tis time, the lever should be kept fre. 5 moving tothe right andi. Of S55 Wate sue nate comecitg wd roves sroatiyby] 3-6 At position 0%, secure tne controt motor lever to the main shat6. BCR MESROLT—2KMALET, RESEOLOHLES, 65 RENE S ORE ES MORI Mig sieomeBL TC 7. St ERESS 1-1 Om ORE s3BM—RON MON EBERT) Yighator [SH] Bm eLR: tate [SH] anes: 7-2 Loves RARE EE IMEMC] RECA ON SOVIET) Vaghado® TSLI EM HEL AM 100% enee, PEL UN BBSROMEREERSLOM, BSHORHERGEMERCELUD, JRLCEORSERREEDT. 4 BLnBecsvben ness BaHT Ome (SLI MMAS. mats. Vvas-FH ORO FMB. MESA SOMA TIO MAT AAO males SokOTsOT, Be OMBLL SU Bowes Pree HERE SHALAL EAS Ste SNS SH-TM escans AMTRNE RAT E0825 “Rte aE Lo9) 2985-25"). FACORDEDESIES 07-0027 RRBTRECRSEAR REREM ‘Ris Fe (02) 3060-1251 (FE) FAXCOS) SHB 1288 RRER PRECAUTIONS DO NOT atiemet to switch the motor between normal and ‘teverse rotation by using contacts C. In addition. be sure to add an interlock circuit t0 the switching circu, Diiake a briet hat between normal and reverse rotation to switch between both, Prevent a surge cu the control motor. Failure to do this could cause the drive cepacitar to open. To be ‘worse. Repetitive surge currents could cause excessive currents to overheat the capacitor, eventually leading to fuming and firing. ‘tom entering the supply power circuit ot HMR IUS CCR ORD TSC RM TECENRUETOTE TREO, Specteavors sijct ta cnange witout note, NISSYO INSTRUMENT CO.. LTD. 10-33, Nitaka 4-chome, Yodogaws-tu, Osaka, 532-0083, Japan Phone i Oseka (08) 6295-1261 FAX : (C8) 6395-1986 2005.8, 500 Peinted it Javan "8sysmac CQM1 Programmable Controllers CAUTION! Replacement timing Se 1) Program Control ter approx. years 707 YF © 10E 2) AC/DC Converter apprex. 7years AC/DC DN ~F- #® 1%CPU Units ‘There are four diferent CPU Units. These are listed inthe following table. The four models can be thought of in two groups: Thase which support Inner Boards and a Communications Unit, and those that do not, There are also di ferences between the CPU Units in program capacity, VO capacity, the avail- abiity of EM, and the availablity f @bull-in AS-232C por. Wodel | WO] Program] CPU | DM] EM ]Bulltingeriel commu] Inner | Common ‘number | capacity | capacity | Unit | capacity | capacity | nications ports | Boards | cations (points, | (Kwords) | bulltin | (Kwords) | (Kwords) [Peripheral | RS-2320 | es 308 input Te teleipea note) points \ comm [sia (182 foo 16 6 é YES VES | Susported | Supponed CPUs! | [coin 72 6 Tione CPUst | fcamine [ase 32 3 ior Rot joPuzt _ supported |supporied coun | Re erutt l Note /0 capacity = No, of input points (< 256) + No. of output points (< 256), CPU Unit Components — stiders sede secure ajacent Uris. Battery Compartment Cover Open his cover acon te bate, BP cuts an omar Caster. LED indicators rang Conecle or Connector $compater urring OX Progammer fo Us hora ‘iornippets bt Link and no-petool Sybingeomecon commurietors, 16 Inpute Built into CPU Unit G-202C Port except COMIH-CPUTI-E) Used or Heel ine nesprotocn, 11 Data Lint or NT ink (11 moce) communications ‘a enttral deve or thar Ps. Fmove iss govers when ‘mounting ines Boards, | inner soard siot2 (rght set) Use tus atta mount # Migh-speed Ceuntat Board Psa YO Boara, AbsalutaEconsr Inerace Board, Analog Seting Board, or Aniog VO Boare Inner Board Slot 1 (tsi) "ite dat eeu a Heh speed Counter Boor ‘io Seng Bove. er Serf Commuratose Sar.DIP Switch Settings The ilustraion shows the factory settings of the DIP switch. The factory set- tings are also given in bold inthe folowing table, Pin_[ Usage Soting Fanaion T [Wate protector [ON | User program, read-only DM (DW 6144 to OM GSBA), and FC Souup (OM BGD0 To DD 656) cannat bo writen fram & Programming Device. [OFF —| User program, reac-onyy DM (DM 6144 te DM 6866), and PC Setup (OM 600012 Di 655) can be wren trom a Programming Device. 2 [itowansiar JON Avto-ranster enabled. rom User programs, read-only DM (DM 6144 io DM 5568), PC Setup (OM 6600 to DM cette 8855, and oxpancionIncrucon Information stored on the Memory Cassov wil bo taneforsdto the CPU Unt cutomatiealy a startup. iin 4s set to OFF, howaver, expansion instruction ‘formation wil not be wans- fered andtho detaut sotlngs Wil be veod. [OFF [rto-boo ceablod >| Prograraming [ON [English Conti dlay | QFE Fae niaga wrod Her BOM Wats WH Ds Baad Taparacs languoge ith tha Japanese version of system ADK) [> —TExgansion [ON | Expansion insirucions set by user. Normaly ON when using a haat compu lor instruction programmingimenitoring. (Sse rote 1), sottng [OFF | Expansion insrucons set o dtaut [=] Seva comman [ON | Peripher port and R-252C por on CPU Unk convolied by standard soitnga calons port (Host Lik, start, even pay, 74 data, 2 stop bt 9,600 bps), satires tpn 7 ie set to OFF, however, hs seting is ignored for tho peripheral port. [OFF | Pergheral por controled by PC Setup (OM 880 to DM 6854) and RS-2820 port eanvated by PC Setup (OM 6645 fo BM 0548), TS (ea0 | User dator- [ON |The seting of pin 6a sored ac the ONOFF statue f AR O7TE. pin Be ON, AR note 2) |mined stig [ope —|O712 wile ON. 1 pin 6 6 OFF, AR 0712 wi be OFF 7 Boe [ON | Progiamming Devos ober tan a Progamming Consolo can be conneciod To he [connocted to peripheral por. [peretoralpot_|[GzF”—~|Gniy a Programming Coresla can be connesed othe peripheral pon fa(eeo [OX Froiseai [ON [Use OX Protocol or Serial Gommunicatons Board rote 2) |enabie [OFF {00 not use OX-Preioco fr Serial Gommunteatons Board Note 1. When pins ON, tis possibie to change he assignment of function codes {or expansion instruction. f power is turned ON with pin 4 turned OFF atter function code assignments have been changed, the settings wil return to the default settings and the information for the expansion instructions ‘were changed will be lost. Also, Ifpin 4 Is OFF, expansion instruction infor ‘mation will not be transferred trom the Memory Cassette, ‘The ON/OFF status of pin 6 is mitrored in AR 0712, so pin 6 can be used ‘as an option switch in the user program through AR 0712, on onIndicators FUN nacatr (Greer Uphewnen ecru Ut gen normal Lesa peeeres| ra SPEED eC] — input Status inateators on BEGHCGOD||— inficstes ins ONOFE status ofthe input bits in 1R 000 Eom ‘Sareaponang's he CPU Unis tute pst paris — grrovatarm inaeator (Ree) | -— Ounpt innit ince atr NH (veto Fiat enmeege | | Lge when ne Quipa OFF St Cae urs ON ronvaial ererTse CPU Uni{ | Odtpas tem athe Oui Units wi un OF citcontme ooesing. | erphera Port ncleator(PRPHL (sow LUghts when heres a fatal, | PlcPas when ing CEU Und is eompuriaatrg wth another dovce Byer chu Umteneton | 4 Be area po snd a etauts wil _—— guitdn 89-2226 Pont ncieator (COMM YeHow tin ee ashes ne re CPU Onis crane ty anc cave ‘eens RS.202C port Nol supported by COMI COTY inatesior | Color] Stotus Weaning RUN |Gieen [Lt ___[ PC ls operating orally n MONITOR or RUN wode Nott] C has stopped operating while in PROGRAM mode, or has stopped operating due toa fatal error. ERAVALM |Red [Lit [a fatal error has occurred. ‘The CPU Unit wil stop operating, and the outputs from all atput Units wil turn OFF. Flash |Anorefatal eror has occurred, ‘The CPU Unt will continue operating [CPU Units operating normally oa watchdog ter ewor has occurred, INA Yellow [Output OFF Bit (SA 25212) has been tumed ON. [The outputs fom all Output Units wil wen OFF. Nott [Output OFF Bit (SR 25212) Is OFF. PAPHL |Yelow [Lit [CPU Unit is sending or receiving va the peripheral port. [Notiit_ [CPU Units not communicating via the periphoral port. CoM |Vorow [Lt [CPU Unitis sending or receiving via the builtin RS-2336 port Natit JPU Units not commanicaing via tho butin RS-23E porMemory Cassette Always turn off power to the CQM! before installing or renoving a Memory Cassette. ® Open the installing part of Memory Cassott. ® Resove the bracket of Menory Cassett. @® Resove the Menory Cassett while the lever is picked up. @ Slide the Memory Cassette into the CPU Unit on the tracks provided, Press the Menory Cassette in so that the connectors fit securely. ® Re-attach the bracket as shown below and tighten seres. Mounting brackst © Close the lid of installing part. IL ROM Version 4 EEP-ROM Always turn off the CQ and resove ‘the Monory Cassette vhen changing the write-protect sviteh setting. Ou =) “00 01 ef ‘aE EP-ROM ‘The EPROM chips Listed below can be uused_in the Nesory Cassettes, ROM Version swi | SW2 276128 Orr | OFF +[ 27256 ON | OFF ell EPROM Install Install an EPROM chip onto the senory cassette as shown in the following diagran.Power Supply Unit ‘The following diagram shows the basic components of a Power Supply Unit. Power indicator Utithen powers beng supplied Exemal tominale 1/0 Units ‘The following diagram shows the basic components of an VO Unit Indicators Indigate the ONOFF status ‘of 119 tormials, Tre ROY in: Seaton Terminale ‘The 1/0 Unit's terminal blocks are renovable. Be sure that the connector tabs are locked in the vertical position, as shown in the follow ing diagran, To remove the terminal block, push the connector tabs to the sides and Lift the terminal block off of the connector, as shown in the folloving diagram, (Open this tab as widely as nacessary.PC Assembly and installation Connecting PC Components The Units that make up a COMI PC can be connected simply by prossing the Units together and sliding the locking tabs toxards the back of the Units. @ The following diagran shows the connection of tvo Units that make up a COML PC. Join the Units so that the connectors fit exactly. @® The yellow Jocking tabs at the top and botton of each Unit lock the Units together. Slide these locking tabs tovards the back of the Units as shown belov. @ Attach the End Cover to the Unit on the far a Be sure to attach the End Cover to the Unit on tho far right side of the PC, ‘The PC will not operate properly if the End Cover is not connected. DIN Track Installation ® Release the pins on the backs of the COMI Units, ‘These pins lock the PC to the DIN Track.@ Fit the back of the PC onto the DIN Track by inserting the top of the track and then press~ ing in at the bottom of the PC, as shown below. ® Lock the pins on the backs of the CQML Units. FP onsack mousing i> @ Install @ DIN Track Bracket on each side of the PC. To install a bracket, hook the bottom of the Bracket on the borrom of the track, rotate the Bracket to hook the top of the Bracket on the top of the track, and then tighten the screw to lock the Bracket in place. DIN Track BracketsMaintenance and troubleshooting Overview Inspection Power supply CPU supply voltage fluctuation (measured at power torminal block using vottmeter} Expansion I/O unit supoly voltage fluctuation (measured at power terminal block using vometer) VO link unit Link adapter Environmental conditions Ambient temperature in control panel Humidity Dust Mounting CPU and expansion I/O unit firmly secured? Expansion #0 unit cable securely inserted in connector? Screws for external wiring firmly secures? Regular inspections and appsopriate maintenance of the PC are essential to ensure the flllile ol your PC and trouble-free operation of your controlled system. Safety measures to protect he system and minimize system downtime in the event of PC Ieilute must also be taken. This chapter covers inspection ‘and troubleshooting procedures for the PC Inspection items are presented in table form in the first par of this chapter, Ths is followed by a brief review of standard maintenance procedures, The lroubleshooting guide presents the actions that should be taken in the case of each type of failure in easy-to-follow flowchart fore. Finally. alist of the error messages displayed by the programrving ‘consoles given, along with the corrective action. Inspection tems ‘Semicanductor elements are employed as main components ol the PC Semiconductors are, however, subject to deterioration under severe environmental conditions and should oe inspected periodically. The standard inspection cycie is 6 months to 1 year. The frequency of inspection should be increases it required, Ifthe PC is found to be outside the criteria shown in the following table corrections should be made so that the criteria are met, €20 rated at AC 100 to 120: AC 86 10 192V 620 rated at AC 200 to 240V: AC 170 to 264V €20 raied ai DC 24V: DC 20.4 1026.4v Must conform 0 specifications of each expansion VO unit AC 85 10 264V. Link adapter rated at AC 100 10 1204 AC 85 to 192V Link adapter rated at AC 20010 240V: AC 17010 264V Link adapter rated at ACIDG 12 to 24V: AC/DC 10.21026.4V Oto +550 95 10 85% RM without condensation Must be reiatvely dustfree Mounting screws must not be loose The cable must not be loose Screws must not be looseCaution: Be sure that the power is off before replacing the expansion VO or other unit Remember ta defective unit is discovered and replaced, contirm the operation ot the replacement unit. When returning a detective unit to OMRON, enclose a written description of the problem {ithe problem is a poor cable contact, wipe the connector pins with a clean all-catton cloth moistened with industrial alechol, Make certain that there is no cloth debris remaining on the cable before plugging itn, Tools and testing devices for maintenance Screwdrivers (phillips and flat-biaded) VOM or digital voltmeter Industrial alcohol and all-cettan cloth Tools and testing devices for troubleshooting Oscilloscope Pon-recording oscilloscope Thermometer, hygrometerProgramma le Controller Troubleshooting TE CoM Tonormal_status Conjecture of the trouble Troubleshooting Power unit “POWER” indicator Is off Disconnection of wiring on terminal board Defect of pover unit Defect of AC/DC converter #1 Screw up/Replace lead vires Replace power unit Replace AC/DC converter #41 “CPU tit “RON” Indicator is off (“POHER” is on) Defect of nenory cassette Defect of CPU unit Replace memory cassette Replace CPU unit Slow lighting of “RIN” indicator ornaly “RUN” indicator is on 1~2 see after “POWER” indicator is on) CPU unit is exposed on abnornal air tenperature Defect of power unit Defect of CPU unit “Keep normal air tenperature by fan or air conditioner Replace power unit Replace CPU unit CPU unit “ALM/ERR” Indicator [s on (“POHER” is on/ “RUN” is off) Disconnection of 1/0 unit Defect of CPU unit Wipe the connector pins with alcohol cloth. Replace CPU unit CPU anit “OUT IN” indicator Is on ( “POWER” is on/ “RUN” is on) Defect of menory cassette Defect of CPU unit Replace nenory cassette Replace CPU unit AIT inputs are not “OK” (Input_indicator is on) Defect of input unit Replace input unit AIL inputs are not “ON” (Input indicator is off) input is not “ON” (Input indicator is on) External electric source for input is not supplied Supply voltage is too low Terminal board is dislocated Terminal board is disconnected Defect of input uni Defect of input unit Supply electric source Raise electric source Confirm the lock of terminal board Wipe the comector pins with alcohol cloth Replace Input nit Replace input unit ‘Sone special input is not “ON” (Input indicator is off) Defect or disconnection of sensing devise Input on tine is extremely short Defect of input unit Re-adjust sensing devise or confirm Wi Revadjust sensing devise Roplace input unit Tnput is not “OFF” Defect of sensing devise Defect of input unit Re-adjust sensing devise {_Roplace input unitAbnornal status Conjecture of the trouble Troubleshooting ALT outputs are not “ON” (Output indicator is on) External electric source for output is not supplied Supply voltage is too low Disconnection of terminal board Dislocation or Loosing of serevs on terminal board Disconnection of terminal board Defect of output _unit Supply electric source Supply rated voltage Confirm the lock of terainal board Screw up all screws and confirm the lock of terminal board Wipe the connector pins with alectol eloth Replace output unit ALL outputs are not “OK” (Gutput indicator is off) Sone special output is not “ON™ (Output indicator is on) Defect of output unit External electric souree for output is not supplied Supply voltage is too lor Dislocation or Loosing of serews on terminal board Disconnection of aux. relay for output unit Terminal board is dislocated or disconnected Defect of output unit Replace output unit Supply electric souree Supply rated voltage Serew up all screws and confirm the lock of terminal board Replace output unit Wipe the connector pins with alcohol cloth Replace output_uni ‘Sone special output is not “ON” (Cutput indicator is off) Disconnection of aux. relay for output unit External output circuit is not in position Defect of output unit Replace output unit Confirm output viring Replace output unit Sone special output is not “OFF” (Gutput indicator is off) Disconnection of aux. relay for output unit External output circuit is not in position Defect of output ut Replace output u Confirm output wiring Replace outout unit Sone special output is not “ON” (Output indicator is on) Defect of output unit Replace output unit Output is “ON/OFF” irregularly (Output indicator is on/off accordingly) Dislocation or Loosing of 5: Disconnect i Defect of power unit Defect of AC/DC converter #41 Serew up all serews and confirm the lock of terminal board Confirm the lock of terninal board Replace power unit Replace AC/DC converter ##L dicator is not “OV mn) [input/output (Operation is nornal condit Defect of input/output indicator Replace input/output unit #1 Use of COM-PDOZE Tor power unit Operation svitch for each unit must be “OFF” shen cperation switch for burner control panel is turned “ON” in order to avoid accidental operation.Appendix A Standard Models The parts with or mark is installed in control panel Power Supply Units Tame] ‘Specifications ose Trienaion | Rated worse” | Aiowed voltage | utp eel ‘me capo | [aS Foner Sony [tow BOVKE [ESOS VAC [TB cones [oR cee Unis soca He __ bow aVOCOEA jCGuiPARS —~JUGLW "roma VAS ow taevae [pow faevecosa —|eawreaaie |W. ce ___ soars edt arevac [BE Power ‘Supply |24V OC [200 28 VDC sow a ‘COMT-POUZS | [UC NL CE CPU Units (with 16 built-in DC input points) Sea Speciation’ West | Iematanat ‘Memory ‘capaci juin juitin RS- | Support of mt beseeaed % [Hecepseir rman | Sanco | SHimer | Beene | doade_| inet | Progen Sakeads [BS poins [ve 0S — Vo i ire conor Tene omar: 3 kwaree jes er leowinceuz | Program: 7.2 Kwords (512 poinis [Yes Yes |COMTH-CPUBT (UC... GE lbMtatea:¢ Kwores | I ve Pra: 132 Kwoce | i | eamnccauar Trent ce} lemaree:ekwoos | i | 1/0 Units Input Units ipa Spectators Weaet aration [Se vous para, Wie TV BC Tapandan conne, REET TS a) [COTTE Le pois, 12V OC (6 panileonmon <1 deat) cousbe Ju. 8 pons, 2 VBC (16 panlcormon <1 seat) jeamrbTe Jue Nee | [32 painis, 12V DC (22 paintsfeommon) — ~ feanrso772 uc tee Sz pons 24 V6 (92 ponieonnan) [cawraons ——Ju.ew16e 32 poms, 24 VDC (32 poiseermon = Gaui) icawroza—_|u-6.0e JAG inputs [8 points, 100 to 120 VAC (8 pointsicomman) 7 [COMIA121 [U.6.0 CE Sports, 2009 40 VAC @ pontwoner) SaMTIAGET ‘Output Units att Spach Wade] aerators “Standards [eamtast a [rparie ZRO WAS eng = Tapa VDE TA Aa lndapenaan commons COM BHT & ous 18 pnt, 258 VAG (eo =1.004V24 VOC BA (AUDA com oom GNC poms, SO VAG 2 A cot = 100424 DC A, epeneEN cea icauiocees |e franacior — [a por, 24 VG 2A (6 AU, omcoreon frauen —oen ce Jourputs 15 points, 50 mA at 4.5 V DC fo 300 mA #1 26.4 V DC, 16 pointsicommon [cam1-op212 re [a2ponte masta sVOCtoimAnlzeavOC SS ‘c-oozis | : [repens 24 V0. 200, PNP eats [oawi-osea q prs. 24 VC 1.0, PNP ouput (4 AU, hor-cweitprvecion ieami-ooais Se pons, 24 VOC, 05 A/PNP oupula (6 AlUni, sor Seut preston lcauronas ee [ae aus pois, 8A 10 a 240 VAC. bo chee wih powiakonvmon eae lcamonzar Jue. [Spore 04 Rat TOO Te VAG two crew pistearmon and? Foo [COMT-OREE? CE ey iBART RVKI-F B28 OMRON Corporation JAPAN. Indusicial Business Group : Nissei Building 14F, 1-6-3, Oheaki, ‘Shinagawa-ku, Tokyo, 141 JAPAN © OWGON corpovstion. OER OU Ke OR UREA memRNARNS (B oweoN asiacraciic PE. LTO. @ OMRON CACETRONCSPTY. 70, OMEN EUROPE BY oven FLecraOWeS NE! OOMNON Canadas ARPoP Seeee ea tai ore, ia genenorsoras ast a 9 0 HER. MURR ERA NSMAMHD ET. STiCCU er Va eee Ree aR ese INSTRUCTION MANUAL— General instruction UFiltrate saraple water, if turbid. 2]Pill & buretie with a reagent up to the highest “0” mark before titra BYScale of whi All ie burette shows P-Atkalinity, keinity and Total Hardness as mg CaCo2/1 ‘After ench wse, wash carefully the graduated cylinders, beakers, colorimetric tube and et, with fresh water. SIIE the product touch exposed skin wash immediately the affected area with fresh weter. the regente sealed,and store them in a dark, cold DAlizerin yellow pH test paper (For boiler water, pH 10.0 te pH 120) 2\Procedure Obip the pH test paper in 2 sample water. @compare the developed color with the color standard chart, 2.P-Alkelinity (mgaCOs/!) Reagents [(a)lndicator Gor P-Alkalinity) ] Uib)No.1 Reagent {for P-,M-Alkalinity, Produce collect 50m! sample water (after filtering, if turbid) into beatker. @AAd 4 drops of Indicator. {f red color appears, P-leainty ie present) ‘@Titrate with No.1 Reagent until the reddish purplé color completely disappears. Record vessl in P-Alainity mg CaCOs/1 (Keep this sample for anaysis of chloride ion) 8.M-Alkalinity (mgCaCOs/!) Reagents, [itbetcat for M-Alkatinity) ] (bYNol Reagent (for P-, M-Alicalinity), 2Procedure Coliect 50:n! of sample water into bealk @Add ¢ drop of Indicator. @Titrate with No.1 Reagent untill the bluish green tune to a grayish purple coler. @Record result in M-Allcalinity (meC Def) 4.0nloride ion (mgCI"/1) VReagents (OXea Reagent (for Charide toy) (oINoB Reagent (for Choride ior). 2yProcedure: Collect. SmI of sample water into bealker. NOTICE: The description in this manual are subject to change without notice on account of remodelling or inprov: ®Add Iml of NoA Reagent: @Titrate with NoB Reagent until yellow color tume to light. brown, @From the ml (a) of NoB Reagent calculate themg/l of Caloride ion as follows. Caloride ion (mgCIl}=(n8)-3 Note:For the analysis of boiler water, use the same sample that has been used for determination of P-Alialinity, E.Toial Hardness (mg0a00y/!) Reagents: = {fa)No. Reagent (lor Total hrardne (©)No3 Reagent (for Total hardness) (indicator (for Total hardness) Note'This Indicator may lose the fluidity at lower tempe- ure, and use Indicator after heating by hot water. 2Procedw ‘@Collect 80ml of sample water into beaker. @Ade al of No.3 Reagent,and 1~2 drops af the Indicator. @Titate with No.l Reagent wntil reddish color disappears, @Record result in mg/i Tote] hardness as CaCO: 6.Phosphate ion (maPO!"/\) Reagents , {(a)No.1 Reagent (for Phosphate ion) | No? Reagent (for Phosphate ion) Note:Before use of No2 Reagent the attached powder reagent should be dissolved into No.2 Reagent. Effective period of this Reagent is 1 month UcdNo.s Reagent (for Phosphate fon) 4 2)Procedare DCollect a sample water (after fi colorimetric tube up to Smal mark. @Add No.l Reagent up to 10m} mark. @After | minute,add No.2 Reagent up to 12.5ml mark,and mix OsAfter § minutes, edd No Reagent slowly yp to 25ml mark. (Note:Temperature should preferable be kept at 20 to 30 0 @aAfter 10 minutes,trasnfer it to the left side colorimetric cell of dark box. Fil the distilled water in the right side colorimetric cel of dark box. Compare the developed color with color stendard slide. Record the number in mg/l es Phosphate ion ering, if turbid) into Kurita errr) nt of the product,THE BASE OF WATER TREATMENT TECHNOLOGY |S ANALYTICAL TECHNOLOGY ASY TO ANALYZE AT A JOB SITE ei tces: KURITAS WATER ANALYSIS, kit ( FOR BOILER WATER aa CONTROL) Wh the advance in water-treatment technology, various chemicals have come ini use, Evaluation ofthe elects ofthese hermits isan essential ask ir weter quelty changes prior ta treatment _ Analy oii purposo mast pected daily 0 accu: ‘The analysis must be performed sity ard al vais pots Kurt's water ensiysis Kit KW+t fully meets this requie: ment, as tis compan sto aide vay of fas tom:Whenusingany ofthe reagentsimarked with an astansk (9), fit a nozzle cep on the bot. Analytical tems Analytical toms by basie set (oH 2) PeAtainity 49) MeAtatinny #4) Chlorides (5) Hardness (8) Phosphate fon ‘Anaiyticel items by optional sel (7) Hydiaine (8) Silica ion (8) Suiurous ion 130) Rasidus chlorine (1) tron fon (12) Calcium hareness> Hada Boiler HANDLING MANUAL FOR EXHAUST GAS ECONOMIZER TORTOISE EncIneERING CO., LTD. 700, KITAGAWARA, MASAKI-CHO, IYO-GUN, EHIME PREF, 791-8181 JAPAN ‘TRL +81-89-984-1851 FAX 481-89-984-8988 SRM 200751 ACONTENS 1. GENERAL DESCRIPTION ~~ 2, STANDARD CONSTRUCTION-~ 3. PREPARATION BEFORE OPERATION ~ ee Inpe ction and Chock of tho Exhaust Gas Economizer renee TS pH ction of Attachments and Preparation for Operation~ 4, CLOSEING OF SAFETY VALVE 5. POCEDURE FOR OPERATION - aration for Operation of Operation ~ ng Operation of Operation 6. CAUTIONS DURING OPERATION. uation of Boiler Water Level ~ uation of Pressure~ tenance of Heating Tubes 7. OPERATION CONTROL AND FREQUENCY- 8. COUNTERMEASURE AT THE MOMENT OF OCCURRENCE OF A SOOT FIRE tire Checking Method ~ rine COUR termeasure Whon the Casing is Heated Extraordinarily High: geney Measure When Soot Fire Occurssal after Extinguishment 9. CLEANING OF HEATING TUBES~ Proce dure dudg ment of Finish of Cleaning 10, PROCEDURE FOR REPAIR AND REPLACEMENT OF HEATING TUBE gency Measure dure for Replacement, of Heating Tube 11. REPAIR,1. GENERAL DESCRIPTION This exhaust gas economizer generates steam by utilizing exhaust gas from the main engine on a voyage and supplies steam to various parts, using a boiler as a steam/water separator Since the heat source of the exhaust gas economizer is exhaust gas from the main engine, the evaporation is subject to the output of the main engine. 2, STANSARD CONSTRUCTION The exhaust gas economizer uses an auxiliary boiler as a steamAvater separator. Cireulation water is fed to a nest of heating tubes by a circulation pump, water flow is from the auxiliary boiler through the inlet header of the exhaust gas economizer where it is heated by exhaust, gas and returned to the auxiliary boiler. From there steam and hot water are separated, and steam goes out for use through a steam outlet valve fitted to the ausiliary boiler. Feed water is supplied to the auxiliary boiler, 3. PREPARATION BEFORE OPERATION Inspection and Check of the Exhaust Gas Economizer The exhaust gas economizer shall be delivered after hydraulic testing and cleaning by the maker, but please cheek following points. 1) No foreign substance on the fixing hole for each attachment. 2) Fastening state of bolts for each removable door, Before fixing the manhole cover, please check the following points. 1) Fastening state of packings. 2) Just before fastening bolts of manhole cover, make sure that no ones is inside. Inspection of Attachments and Preparation for Operation 1) Check the indication and position of the pressure gauge. 2) Adjust the safety valve and check the closing of it, 8) Check the operating state ("Open” and "Close") of the attached valves and the tightening allowance of the glands. 4) Check the soot blower. 5) Check all piping for heat insulation. 6) Check for loose bolting of the attachments and the state of fixing of packings.4. CLOSING OF SAFETY VALVE After removal of the cap of safety valve, check the fixing state of the safety valve and the exhaust gas pipe, then, close the circulation water outlet valve, start to operate the circulation pump, and measure the pressure increase. Just before the pressure reaches the close pressure, lift the valve bar and confirm a gush of steam, After dust and other foreign substances are completely blown off, close the valve, The closing pressure should be adjusted so that the steam can by itself blow off at a pressure not. exceeding 1.08 times the exhaust gas economizer design pressure. Repeat the tests until the valve blows open and closes at the correct operation pressure. 5, PROCEDURE FOR OPERATION Preparation for Operation 1) After checking each valve for operation, keep the pressure gauge root valve open. 2) After drain is discharged out of the soot blower, try the operation of the soot. blower. Start of Operation before start of main engine) 1) Open both circulation water inlet. and outlet valves. 2) Open each valve on both suction and discharge sides of eireulation pump. 8) Start the circulation pump, 4) Open each air bent valve, and if circulation water is discharged through it, close it. 5) Open drain discharge valve on steam headers and let drain. 6) Check each joint and piping for leakage. 7) Check cireulation of boiler water by circulation pump pressure gauge. During Operation 1) Cheek each valve for leakage from glands and packings. If leakage is found, tighten them further. 2) Check each joint on the piping for leakage, 8) Check the water level of the auxiliary boiler. 4) Check the pressure of the auxiliary boiler and exhaust gas economizer. Stop of Operation (after main engine has stopped) After the main engine has stopped, continue to operate circulation pump for 2 hours or more further, then, 1) Stop circulation pump: 2) Close valve on both suction and discharge sides of circulation pump. 8) Close both circulation water inlet and outlet valves6. CAUTIONS DURING OPERATION Fluctuation of Boiler Water Level Since the exhaust gas economizer utilizes exhaust gas from the main engine, the evaporation rate fluctuates according to the change of load by the main engine, In connection with that, the circulation water changes and the boiler water level fluctuates greatly. For example, if the main engine starts to work while circulation pump is operating, steam starts to be generated in the exhaust gas economizer and circulation water in front of the air-bubbles zone is suddenly driven out to the boiler, resulting in a temporary vise of the boiler water level. This is called "bulge phenomenon’, On the other hand, when the main engine stop, generation of steam ends in the exhaust gas economizer, and the boiler water is foreed into the space for steam in the exhaust gas economizer by the circulation pump, resulting in a temporary drop of the boiler water level Besides these factors caused by the starting and stopping of the main engine, the boiler water level also fluctuates due to starting and stopping of the cireulation pump. Accordingly, the boiler water level should be controlled taking account of these factors, Fluctuation of Pressure Since the exhaust gas economizer is designed to evaporate a certain amount determined by the load of the main engine in normal working condition, the boiler pressure fluctuates: according to consumption of steam on board. When consumption of steam decrease, the steam pressure increases, but when the pressure reaches a certain level, the surplus steam, dump valve opens and the surplus steam returns to the condenser. On the other hand, when consumption increases and the steam pressure drops too low, the boiler can be ignited and additional steam generated. Maintenance of Heating Tubes Heating tubes of the exhaust gas economizer are of the numerous bend type. When soot adheres and accumulates on the heating surface of heating tubes, the efficiency of the exhaust gas economizer decreases and the temperature of soot itself increases making a soot fire likely to occur. For this reason, the heating tubes should be kept as clean as possible. For that reason a soot blower is installed on the exhaust gas economizer, As long as the soot, blower is used frequently and works normally, heating tubes can be maintained in an acceptable condition. However, the tubes may become excessively soiled due to infrequent use or failure of the soot blower. The stained condition of the heating tubes should be carefully observed and those tubes should be properly maintained, Recommended method for maintenanes is ad follows: 1) Measurement of dratt loss. 2) Measurement of exhaust gas temperature. 3) Visual inspection of the heating surface.7. OPERATION CONTROL AND FREQUENCY 1) Logbook: Record all the items necessary for control of operation such as pressure, temperature, Every time on duty feed water quantity, soot blowing, ete, as well as boiler operation diary. 2) Soot blowing ~ Every time on duty Hold down the steam load and open drain fully, then, operate soot blower slowly. Use the soot blower for as long as necessary to remove accumulated soot. 8) Measurement of Draft Loss ‘Once a day Measure it at the exhaust gas inlet side by means of a manometer. 4) Measurement of Exhaust (tas Temperature ‘Once a day Measure the temperature at the exhaust gas outlet side 5) Air vent- Every restart of operation 6) Visual Observation of Heating Surface- Every anchoring time 8. COUNTERMEASURE AT THE MOMENT OF OCCURRENCE OF ASOOT FIRE If a soot fire should oecur in the exhaust gas economizer, the following measures should be taken. Soot Fire Checking Method When one of the following phenomena is found, you should suspect a fire in the exhaust gas economizer, and when examining it, check whether the easing is heated or not, 1) The exhaust gas temperature has suddenly increased, 2) The exhaust gas temperature does not drop at anchoring, 8) Sparks come out from the funnel. Countermeasure When the Casing Is Heated Extraordinarily High 1) Immediately stop the main engine. 2) Continue to operate the circulation pump. When the pump is not working at anchor, immediately start the pump and supply water to the exhaust gas economizer. 8) Open the manhole and inspect the inside,Emergency Measure When A Soot. Fire Occurs In case a soot fire is found by inspection of the inside, 1) Immediately sprinkle water by means of a hose through the manhole. 2) After the fire has been put out, clean the inside of the exhaust gas economizer with fresh water. Disposal aftor Extinguishmont 1). Enter the exhaust gas economizer and observe the damaged part and check the extent of the damage, 2) Report the damage to the maker to get advice. 8) The maker will give specific instructions, but in principle, continue to sail according to the following instructions: In the case of a burst of heating tube, you should continue to only after you eut it and use the stopperhereinafter detailed) 4) During navigation, observe the following cautions: (1) Operate soot blower more frequently. (2) Checks more carefully the gas temperature and the draft loss,9. CLEANIG OF HEATING TUBES Procedure 1) Measure pH value of water to be used before cleaning. 2) Make sure of the stop of the main engine, 8) Open the drain vent valve on the bottom of the exhaust. gas economizer. 4) Close exhaust gas inlet pipe in the exhaust gas economizer with canvas on inside as following sketch, 5) Close access hole cover. 6) Start cleaning with water, then make sure the water is flowing in to drain pipe, which comes out after cleaning, 7) It is difficult. to check exactly the effect of cleaning heating tubes during water sprinkling So you should not stop water sprinkling when only visible areas are cleaned. If cleaning is not carried out sufficiently and soot is left, the soot left, will dry and harden, and everitually will not be removed. Iso, adherence of more soot. is facilitated. Therefore, soot, should be removed carefully by water sprinkling. 8) After water cleaning, take out the canvas from the inside of the exhaust gas inlet pipe, 9) Measure pH value of the water which comes out after cleaning. CANVAS Judgment of Finish of Cleaning 1) When the difference in pH value of cleaning water before and after sprinkling reaches 1 or less, and muddiness is not observed, temporally stop sprinkling water. 2) Enter the exhaust gas economizer and check the soot loft locally. 8) Cleaning is finished when it is judged that there is nothing accumulated. -10-10. PROCEDURE FOR REPAIR AND REPLACEMENT OF HEATING TUBE, When heating tube has burst due to soot fire or some other reasons, repair or replace it as follows. Emergency Measure As an emergency measure until an unusable tube is replaced with a new one, the unusable heating tube should be cut out, and a stopper used on the outlet and inlet of the header respectively so that the exhaust. gas economizer ean be coutinued to be operated. The procedure is as follows’ 1) Completely blow off the water in the exhaust. gas economizer. 2) Remove header covers on both inlet and outlet. 3) Cut out the heating tube. 4) Weld a tube plug on heating tube, 5) Fix the header covers again in position. TUBE PLUG Nall | HEADER COVER too), A ee GAS CUTTING | Procedure for Replacement: of Heating Tube In the case of a burst heating tube, a permanent replacement, should be made. 1) Blow off all the water in the exhaust. gas economizer, 2) Remove header covers on both outlet and inlet. 8) Remove the casing door. 4) Cut out the heating tube. 5) Loosen and remove the bolts for heating tube band. 6) Remove the cut out portion of tube. 7) Finish the header stub by grinding. 8) Position a spare heating tube and weld it to the header stub. 9) Carry out hydraulic test at a design pressure and confirm that there is no leakage, 10) Fix the casing door in place. oie11. REPAIR 1) Areas exposed to pressure Repair should be made carefully using materials as specified, strictly conforming to the maker's instructions. 2) Other areas Repair should be made carefully using materials as specified, 8) Attached valves and other attachments Repair should be made carefully, consulting with the maker(s) concerned.INSTRUCTION MANUAL H 1627 TYPE Full Bore Type Safety Valve TOA VALVE CO.,LTD AMAGASAKI, JAPAN DATA No. 40038 Rev oCONTENTS. Cautions for Safety ---+- Structural Dimension drawings Description of Function Installation of Safety Valve Adjustment Disassembly and Assembly Lapping and Repairing Inquiry for this Safety Valve - 10 13 16CAUTION FOR SAFETY Observe without fail . To all persons who use, install, and maintain the safety valves. Precautions described here are very important facts to operate the safety valves seourely, especially concerning injury to persons or damage to equipments, Prior to use, handle the safety valve correctly after perusing these precautions. The precautions are indicated in divisions of “Warning” and “Caution” . in order ‘to indicate urgency and magnitude of danger and damage which are presumed to occur when the safety valvo is handled mistakenly. In addition, when the safety valve is handled, the trained expert should contact and ‘operate in accordance with this Instruction Manual. Description for Division of Indication If handled disregarding this indication, the content presumed to cause possibility that persons would be killed or seriously injured is indicated. WARNING If handled disregarding this indication, the content presumed to cause possibilty that persons would be slightly injured and to cause only material danage is indicated. CAUTIONPrevention of Accident Due to Falling, etc. 1, When lifting the safety valve, use an proper wire or sling after confirming valve weight. 2. While lifting the sefety valve, do not stand under the valve. 3. Do not piace the safety valve on the unstable condition in which the valve WARNING may be falling and result in accident. Damage Prevention of Safety valve 1, When lifting the safety valve, do not use the lever and stem 2. Safety valves should be stored indoors. If drenched with water, quality may be deteriorated and may be damaged. 3. Do not place the safety valve on the unstable condition in which the valves CAUTION can be falling and result in damage. Prevention of Accident Due to Falling, etc. 1, When lifting up the safety valve, use proper wires or slings after confirming the weight. 2. While lifting the safety.valve, do not step in under the safety valve. 3. Avoiding working at unstable place. 4. When tightening nozzle flange, the flange bolts should not be tightened WARNING one~ sidedly and gasket should not be protruded. There is danger such as a scald due to steam leaking. 5. Renove dust-proof caps without fail from inlet and outlet of safety valves. Prevention of Damage to Valve 1, When lifting up the valve, do not use the lever, stem ete. 2. Do not use the valves es a foothold. The valve may be injured. Prevention of Accident Due to Pressure Test 1. Use caution adequately for pressure test, and do not exceed the planned velue unconditional ly . 5 5 NING Prevention of Valve Damage due to Pressure Test 1. Fix the test gag so that the end of gag should push the center of stem, ‘and do not tighten with excessive force.Prevention of Accident When Operating and Check 1. Do not pull or lift the lever provided to safety valve . There is a danger to get scald by steam blowing out. 2. Prior to disassemb! ing the safety valve, confirm that pressure is not left CAUTION inside by checking pressure gauge, and start disessenbl ing. Prevention of Damage to Safety Valve 1, When starting operation, renove the test gag without fail or the stem may be bent and the safety value shall fail to open CAUTION(Q) This Instruction Manual is prepared for those personne! who directly handle and operated the safety valves, to understand how to operate and how to maintain the safety valve correctly, (2) Prior to instal lation, disassembling, assenbling or operation, personnel in charge of andl ing the safety valves should stert operating after perusing and understanding this manual. Photos, structural drawings, ete. used in the description are not necessarily of the supp! ied products, but of standard drawings, those are and indicating fundamentals of handl ing works. (@ in this manual all conditions or states probable to occur during operation and maintenance, for example, accidental problems are not covered, therefore if you have questions or unclear points, please contact the nearest office or factory (or our dispatched persons). (@) Various | imited values specified in this manual should be abserved unreasonable handl ing should be avoided and always be handled within limited value. And also, correct checking and repairing should be done to prevent accidents beforehand, (5) Store this manual in the place near the persons in charge of operation and maintenance. Exercise caution again and again that data described in this manual should not be handed over to the third parties even partially without out our permission. (© In the-event that accidents such as malfunction, trouble occurrence, please contact immediately as the following procedures. (a) Confirming contents of Name Plate (Name of product, Wanufacturing No, Capacity, Type .Menufacturing Date ) (b) Confirming contents of Trouble (Including before and after states of affairs, As detailed as possible. ) (c) Please contacts our nearest office, or the address below.) Sales Company TOA SERVICE CO., LTD. Office 660-0054 12-1, 5-Chowe, Nishi~Tachibana, ‘Amagasaki City Hyogo Pref, Japan (Within Premise of Toa Valve Go. ,Ltd.) Sales Dept. Tel: + 81-6-6416- 8866 Fax: 481-6-6419-5656 Tokyo Office 108-0014 34-6, Shibuya 5 choune, Minato-ku Tokyo Shintamachi Bldg. 7 Floor TEL (03)5445-4062 FAX (03)5445-4867 Manufacture TOA VALVE C0., LTD. Head Factory & Office 660-0054 12-1, S-Chote, Wishi-Tachibana, Japan ‘Anagasaki City, Hyogo Pref. TEL (06)6416-a860 FAX (06) 6419-5641STRUCTURAL ORAWING Cte 2S BE210 (FULL BORE TYPE) | Wane | WATERIAC [mip Rewarn Taina RET TT sar singer ste [1 —hietenre stee [7 [srr cy scene“ stains ste] 1 ur SIL i se i est an TLFT SPREE. + rae i i sre WEG EE se [ate re 1] efi He SECT STEE—T_1] [ere ima SIC 1 rs ae icy [ac fpat anesree[] S18 see —foeeee 1 ST Ste] w REA 1 MS ea SIL r| [iT eto sek SP Me Ra [ENTE | POW el Me PLA frre r 2. REINFORCE WELD x 1 Peete ea LP TYPE(LOW PRESSURE. TYPE) DETAIL A CeTAIL 8 TFO TYPE(HIGH PRESSURE TYPE) ut it idan FOR PRESSURE OVER 2MPa, CONNECTION OVER ALL vero os es nue a cpa ss —omninn feu ve "RT| SEAT |e i oust Pad ‘eur itn SOREW SORES eet a gi {Sixty fsoxe7 [ur teapie | iy 8 [ss Tot | a? Sh at 0 1 | Fig] fe ae aoa Leet olboer oe pisteene sr ties p at fe Fi vost wuss ofolss mes re Sar ecuey sr furs] meie—| pte Set | Cop aiace (aoe [nto obers aes [oyecveL-ar Pee [mew st te Som peas aaa nets pars ys Letdecve o-Ps eevee ke Peet FIG] (STRUCTRAL DIMENSION DRAWING)ay | Lipsy a 1 oOo \\ i t < a 1 m | 1 1 ii ii Wt ih 1 t 4 ee _e 1 [- = op ZX 7 ; aL FIG2 (FUNCTIONAL CONDITIONS OF SAFETY VALVE) -6-1, Description of Function This type H1627 full bore safety valve with flat seat and high relieving capacity. A safety valve is required to blow off within the specified accuracy and sureness when the pressure reached the specified value. The reliving mechanism of this type of safety, valve is characterized by tho popping groove provided on the dise which produces an easy popping and also the adjusting ring for better utilization of the dynamic opens (quick and clear) once the pressure reached the specified set value. In addition to stabilized relieving operation, and easily adjusting back pressure, throttle valve is provided to Toa safety valve to ensure secure closing. The tolerance value regarding the operation of the safety valve is according to JIS B8210-1994, (Japanese industr | standards) This tolerance value is indicated in the Table .1, and Table.2 So, Please refer to the Table. 1, and Table. 2. As for parts name, Please refer to the Fig.1. As for function opening, Please refer to the Fig. 2 SPRING FORCE LOSING FORCE BY BACK PRESSURE | ps allow continuing stabilized blow-off. OUTLET The dise Is pressed againet 1118 stopper to Blow down pressure ie adjusted by opening| and closing beck pressure. After adjusting, bx the lock nut surely. STEAM FORCE Back preseure got in through thie gap move to direstion of olosing valve. Stabilized blowolf ie conducted by Utilizing of electing steam and static FIG3 (FUNCTIONAL CONDITIONS OF SAFETY VALVE} -7-Table 1 Tolerance for Popping Pressure (JIS 88210-1994) Unit:MPa(kg/cm’) Set Pressure Tolerance Less than 0.5{5) | +0.014{:0. 14} Over 0.8{8)and less than 2.3 {23] 4: (3% of set pressure) Table 2 Tolerance Blow-Down Pressure (JIS B8210-1994) Unit: MPa{kg/cm*} Popping Pressure Blow-Down Pressure | Less than and equal 0.03{0. 3} Less than and equa! 0. 4(4} Loss than and equal 7% of orereeen tal Popping pressure 1.1 Lifting Lever JIS B8210(Soring Loaded Safety Valve for Steam and Gas ) provides that Safety valve be fixed with means which enables manual blow off. When the lever is pulled up, that Is lifting lever, the stem is pushed up and the spring is compressed, so the safety valve can be blown out manually et lower pressure than the specified popping pressure, (By the stipulation of JIS, whon the boi ler pressure has come up 75% over of the specified Popping pressure of the safety valve, manual popping should be possible. For example, when popping pressure is 1.0 MP2, manual popping can be made if boller pressures approx. 0. 7Mpa or over. ) This manual relieving by using the lifting lever may be conducted, for instance, when leaking caused by scale caught between seat and disc or it is desired to have valve condition test,2. 1 Installation of safety valve 1) It is needed that the safety valve should be instal led as directly and vertically as possible to the boiler. Piping with strong resistance (many corner or long pipe between boiler and safety valve) should be avoided absolutely, and the whole length should be as short as possible and rounded enough to minimize pressure loss in the pipe. 2) When the safety valve is instal led on the nozzle stub, exercise special caution to ensure ‘that there are no dust or foreign materials inside the inlet portion, and install after cleaning. 3). In case of screw-in type (refer to Fig. 1), wind seal tape around the male screw section securely and screw in firmly using caution that seal tape should not be got in the inlet side of safety valve. ‘At the seme time , screw in putting properly a spanner at hexagonal section of seat @. 1¢ ~ wrench on cylindrical section of valve body, or don’ t tighten by a pipe Do not put screwed in outlet of valve. 4) Flange type Sheet packing should not be protruded to fluid passage, and at the same time the bolts should be tightened uniformly and not one-sidedly.2. 2 Fitting of discharged pipe In case of full bore type safety valve, fitting of discharge pipe is especial ly inportant. The discharge pipe should be fitted solidly on the safety valve. The piping methods which we recommend are shown in Fig 4 and Fig .5. hort diseha DE The elbow should be screwed ectly into the outlet of safety valve, and discharge pipe may be fitted to the elbow. In this case, length of discharge pipe should be about 1M, and should be limited to 1.5m or shorter at the longest. AppROX.1 090 WMT 10 1500 oR BELOW? USE SPECIAL THAN THIS OMENSION on ess: WET bier slain Would | scr rearely tn te i | i elbow. Fix the discherse piping to the other Tixed object with wire. But 6) little looseness is needed. I t rat 2 The elbow piping ¢ should be screwed in sufficiently ond bolts should be tightened solidly. Drilling should be done at the eibow side to lot set bolt end get in PROVIDE GRAWAGE PIPE WITHOUT FAIL be | { AppROKL CAUPION NOT TO BE LONGER. ae a oe ai fs, s. | [te |e 20 Reo PRPs 7 69 95 RC + 1/8 2 Reii/a] RP+ 11/4 1 105 RC 1/8 32 Re1iv/2] RP+ 2 100 135 RC 1/4 40 R+ 2 RP+ 2 100 145 | RC+ 1/4 50 R- 21/2] RP+ 21/2 ut 160 RG 1/4 Fig.4. (Installing Procedure of Standard discharge pipe) ~10-age CoOL coon AND. WA8H CONTIN, PLEASE ‘EP SUFCENT CLEARANCE USE SPECIAL CAUTION NOT 10 BE LONGER TW CRSE OF TONG UISCHARGE FIFE (™ Said Bee oon] {BOER MOL TD TOUCH Dsthator pee > fx aschace PPE To Ta auto SEPARATING FROM SAFETY VAL¥E crn pane | {MS iw | ge ete | Ue} Ke ' Pal ION 4 © a i Tel! 7 [x2] a a a a TTL THAN TS DENSON Exercise caution to steam blowing off from back pressure relief hole. Incase where relief pipe is provided, fix as short pine as possible. Back pressure is low (about0.2 MPa or below), so thin stee! pipe is enough to bo used. Elbow should be serered directly into and the drip pan should be fixed to the end of | elbow. [And a long pipe should bo fitted [perfectly free from the safety valve. This piping should be fixed securely outlet of safety valve, to the building ,ete. Non. | Inlet | Outlet | Face to Discharge height of lone Size | _Sorew | Sorew Face [Drain | Drip Pan Pipe [Pie Screw] ‘Giscanee pipe ai] os, sz |t,|t2| 0» | oe joa} ow 84 4 zo |p - 1 |ap- 1 | 69 | 95|Rc-1/8]ac-a/e} iis] oI RP 4/4 215 28 over MIN 25 |r -11/4]ap - 14/4] 70 [105] Ro-1/8] Ro-9/8| 115] > Motsover | RP 1/4 290 MIN az |R -t4/2]Re - 2 | 100 |i95|no-1/4]Ro-a/s| 155] 4"! Neg | RP: 3/8 370 MIN ao [R= 2 |re- 2 | 100 |r4s|no-s/a] rosa} 15] 1M | RP 3/8 370 MTN so |r + 21/2}RP + 24/2] 111 | 160] Re-1/a}ec-a/e} 55] aM Neg | RP* 3/8 400 FigS (installing procedure of long discharge pipe ) -11-2. 3 Hydraulic test for Boiler In the case where hydraulic test for boiler conducted, the safety value shall be set as the Fig.6, and presser bolt should be tightened by hand, and not be tightened by tool such as spanner. If tool is used, there is the possibility of damaging the sten. Tlahten by hand without fail Wr Fig6 (installing Procedure of Water Pressure washer) -12-3. Adjustment As there is the possib ty of danger thet the safety valve pops out during adjustment of safety valve, the boiler pressure should be lowered down to about 80% of popping pressure. 3. 1 Adjusting of popping pressure Adjusting of popping pressure is not usually needed, because the safety valve is adjusted as indicated on the name plate at our factory. In the event that adjustment became necessary, adjustment should be conducted in accordance with the following procedure. 1) Prior to loosening the hexagonal bolts fixing the adjusting screw, make mark on the spring cover and the adjusting serew with magic ink, ete. 2)Loosen the set bolt locking the adjusting screw. 3) Insert the pin wrench (Fig.7) set the lever as a turning tool (Fig. 7) for the adjusting screw (Fig.7), turn to cunterclockwise, and the pressure is lowered. 4) The relation between variation of popping pressure and revolution numbers of the adjusting screw is approximately as the following as a yard stick. tae of Safety velvd 20 2 | seo | 50 ‘Adjusting Soren | 12.59% 10% 7.8% 5% 1/2 Revolution ‘Aajusting Sere a 20% a anevy 1 Revolution Possible range for changing the set pressure indicated on the name plate should be +5% as a yard stick. In a peculiar case, please contact our office. ( If the change is large, it is necessary that the spring is replaced. aa SE ve i ta ansea sc FIG7 (ADJUSTING PROCEDURE OF POPPING PRESSURE} —13-3 2 Adjusting of reseat pressure The blow-down pressure (different between popping and reseat pressure) of the safety valve is adjusted a bit larger than that indicated on the name plate at our factory. However the value may be changed due to stalling conditions, etc., so in this case adjustment is needed at site. Usually, until the blow-down of safety valve is 0. 15Mpa, the aim can be easily achieved by adjusting the back pressure throttle valve. According to the procedure shown in Fig 8 Please adjust the adjustable back pressure throttle valve, Minute adjustment of blow-down a can be easily done by adjust ing the back pressure throttle valve OF When adjustment of back pressure throttle valve is finished, tighten the lock nut adequately so that throttle valve nay not be loosened, Fig 8. (Adjusting Procedure of reseating pressure ) ate